Filter element, systems, and methods

ABSTRACT

A gas turbine air intake system uses a filter element having a seal member with radial projections and radial recesses. The seal member forms a seal with components on the tube sheet of the system and at the end opposite of the tube sheet. At the end opposite of the tube sheet, there can be an assembly cover, or alternatively, an additional filter cartridge.

This application is being filed on 23 Jan. 2019, as a PCT Internationalpatent application, and claims priority to U.S. Provisional PatentApplication No. 62/621,364, filed Jan. 24, 2018, and to U.S. ProvisionalPatent Application No. 62/794,205, filed Jan. 18, 2019, the disclosuresof which are hereby incorporated by reference herein in their entirety.

TECHNICAL FIELD

This disclosure concerns filter for use in air intakes for systems suchas gas turbines. In particular, this disclosure concerns filters andsystems that ensure the correct filter element is being used for thesystem.

BACKGROUND

Air intake for gas turbines, and other such systems, require filtrationof the air so that particulates in the air do not damage downstreamcomponents, such as the turbine. As such, the filters used areimportant, and having the proper filter element installed is importantin protecting the downstream turbine. Improvements in such filtersystems are desirable.

SUMMARY

A filter element and filter assembly are provided that improve the priorart.

In one aspect, a filter element is provided including a tubular sectionof filter media and first and second opposite open end caps secured tothe filter media. Each of the first and second end caps has a sealarrangement along an inner radial surface of each of the end caps. Eachof the seal arrangements includes a seal member having an inwardlyradially directed seal surface and a thickness that varies along theseal member surface.

Each of the seal arrangements may have a same shape as the other.

The tubular section of media can be conical, and the seal arrangementsvary in proportion to each other.

In some embodiments, there can be a seal support, which may comprise aninner liner extending between the first and second end caps.

The thickness between the seal support and the seal member may vary in aradial direction along the seal member surface.

A length of the seal member surface can be constant in an axialdirection.

The seal member thickness may vary by a minimum thickness and a maximumthickness, wherein the maximum thickness is at least 1.1 times theminimum thickness.

The radially directed seal surface may comprise a plurality of outwardlyprojecting and axially extending portions and a plurality of inwardlyprojecting and axially extending portions.

The plurality of outwardly projecting and axially extending portions andthe plurality of inwardly projecting and axially extending portions maycomprise curved portions.

The radially directed seal surface can include at least 2 of theradially outwardly projecting and axially extending portions alternatingwith at least 2 of the radially inwardly projecting and axiallyextending portions per inch around a central axis of the filter element.

The radially directed seal surface can include greater than 20 of theradially outwardly projecting and axially extending portions alternatingwith greater than 20 of the radially inwardly projecting and axiallyextending portions.

In some embodiments, the filter media is pleated media.

In many example embodiments, the tubular section of filter media has around cross section.

In another aspect, a filter element is provided comprising a tubularsection of filter media; and first and second opposite open end capssecured to the filter media; each of the first and second end capshaving a seal arrangement along an inner radial surface of each of theend caps; each of the seal arrangements including a seal support and aseal member supported by the seal support; and the seal member having aninwardly radially directed seal surface and a thickness between the sealsupport and the seal member surface that varies along the seal membersurface.

In another aspect, a filter assembly is provided. The filter assemblyincludes a tube sheet having a filtered air aperture; a tube sheet sealmember along the aperture; and a filter element releasably secured tothe tube sheet. The seal member of the tube sheet has a plurality ofalternating outward radial portions and alternating inward radiallyportions. The filter element includes first and second opposite endcaps; a tubular section of filter media defining an interior volume incommunication with the filtered air aperture of the tube sheet; and afirst filter element seal member along the first end cap having aplurality of compressible alternating radial projections and alternatingradially recesses. The first filter element seal member forms a sealwith the tube sheet seal member in that the tube sheet seal memberinward radial portions receive the first filter element seal memberradial projections; and the first filter element seal member radialrecesses receive the tube sheet seal member outward radial portions.

In some examples, the tube sheet seal member is part of a seal platehaving a collar and a neck. The collar is attachable to the tube sheet,and the neck projects axially from the collar. The tube sheet sealmember is along the neck.

The filter assembly may further comprise a yoke plate secured to thetube sheet. The yoke plate includes a fixture holding a rod removablysecuring the filter element to the tube sheet.

In some example embodiments, the second end cap is an open end cap.

In embodiments where the second end cap is an open end cap, the secondend cap includes a second filter element seal member having a pluralityof compressible alternating radial projections and alternating radiallyrecesses.

In embodiments that have a second open end cap, the filter assembly canfurther include an assembly cover having a plurality of alternatingoutward radial portions and alternating inward radially portions. Theassembly cover may be received within and form a seal with the secondend cap such that the assembly cover inward radial portions receive thesecond filter element seal member radial projections; and the secondfilter element seal member radial recesses receive the assembly coveroutward radial portions.

In embodiments that include an assembly cover, the filter assembly canfurther include a gasket washer and a pivotable handle, wherein the rodextends through the assembly cover and is secured to the gasket washerand handle to removably secure the filter element to the tube sheet.

In some examples, the filter element is one in a filter pair; the filterpair comprising either two cylindrical elements, or a conical elementand a cylindrical element stacked axially

In some embodiments that include a second open end cap, the assemblyfurther includes an additional filter cartridge removably mounted withinthe second end cap. The additional filter cartridge has a media packcomprising opposite first end and second flow faces with flutesextending in a direction therebetween and a sidewall extending betweenthe first and second flow faces. At least some of the flutes have anupstream portion adjacent the first flow face that are open and adownstream portion adjacent the second flow face that are closed. Atleast some of the flutes have an upstream portion adjacent the firstflow face that are closed and a downstream portion adjacent the secondflowface that are open. A band is around the sidewall of the additionalfilter cartridge. The band includes a plurality of alternating outwardradial portions and alternating inward radial portions. The additionalfilter cartridge is received within and forms a seal with the second endcap such that the band inward radial portions receive the second filterelement seal member radial projections; and the second filter elementseal member radial recesses receive the band outward radial portions.

In embodiments that include an additional filter cartridge, the filterassembly may further include a gasket washer and a pivotable handle,wherein the rod extends through the additional filter cartridge and issecured to the gasket washer and handle to removably secure the filterelement to the tube sheet.

In another aspect, a filter cartridge is provided. The filter cartridgeincludes a media pack comprising opposite first and second flow faceswith flutes extending in a direction therebetween, and a sidewallextending between the first and second flow faces. At least some of theflutes have an upstream portion adjacent the first flow face that areopen and a downstream portion adjacent the second flow face that areclosed; and at least some of the flutes have an upstream portionadjacent the first flow face the are closed and a downstream portionadjacent the second flow face that are open. A band is around thesidewall. The band includes a plurality of alternating outward radialportions and alternating inward radial portions.

The band can be between the first flow face and second flow face.

The band may be against the side wall.

The band may be adjacent the first flow face.

In some embodiments, the band is part of an end piece. The end piece hasa plate extending radially from the first flow face. The band extendsaxially from the plate along the side wall.

In many example embodiments, the media pack is coiled, and the mediapack defines a central, open channel extending between the first andsecond flow faces.

In example embodiments, the media pack forms a round construction.

In a further aspect, a filter arrangement is provided comprising firstand second opposite open end caps; a tubular section of filter mediaextending between the first and second end caps and defining an interiorvolume therewithin; and a filter cartridge mounted within an opening inthe second end cap.

The filter cartridge can include a media pack comprising media forstraight-through flow.

The filter cartridge may include a media pack comprising flutes.

The filter cartridge may include a media pack comprising pleats.

The filter cartridge may include a media pack comprising opposite firstand second flow faces with flutes extending in a direction therebetween;and a sidewall extending between the first and second flow faces; atleast some of the flutes having an upstream portion adjacent the firstflow face being open and a downstream portion adjacent the second flowface being closed; and at least some of the flutes having an upstreamportion adjacent the first flow face being closed and a downstreamportion adjacent the second flow face being open.

In some embodiments, the tubular section of filter media is pleatedmedia.

In some arrangements, the first open end cap includes a radiallyinwardly directed seal member oriented to form a releasable radial seal.

The filter cartridge can be removably mounted in the opening of thesecond end cap.

The filter cartridge can be non-removably mounted in the opening of thesecond end cap.

In some implementations, the media pack in the filter cartridge iscoiled.

In some embodiments, the media pack of the filter cartridge extends fromthe second end cap into the interior volume and toward the first end capalong an extension less than half of a distance between the first andsecond end caps.

In some embodiments, the media pack of the filter cartridge extends fromthe second end cap into the interior volume and toward the first end capalong an extension less than one-third of a distance between the firstand second end caps.

In some arrangements, the filter cartridge is positioned within theopening in the second end cap in an off-centered position.

In one or more embodiments, the filter cartridge has an outer perimetershape that is non-round.

The filter cartridge may have has an outer perimeter shape including oneof: a sector of an annulus with rounded ends; a segment of a circle; orbanana.

In a further aspect, a filter element is provided including a tubularsection of filter media defining an open filter interior; and a firstopen end cap and an opposite second end cap secured to the filter media;the second end cap having a center, integrated gasket with a sealmember; the seal member having an inwardly radially directed sealsurface and a thickness that varies along the seal member surface.

In example embodiments, the thickness varies in a radial direction alongthe seal member surface.

In example embodiments, a length of the seal member surface is constantin an axial direction.

In example embodiments, the radially directed seal surface comprises aplurality of outwardly projecting and axially extending portions and aplurality of inwardly projecting and axially extending portions.

In example embodiments, the plurality of outwardly projecting andaxially extending portions and the plurality of inwardly projecting andaxially extending portions comprise curved portions.

In example embodiments, the second end cap has a recessed sectionprojecting inwardly into the filter interior; and the integrated gasketis centered in the recessed section.

In example embodiments, the integrated gasket has an outer diameter lessthan 20% of an outer diameter of the second end cap.

In example embodiments, the first end cap has a seal arrangement alongan inner radial surface; and the seal arrangements includes a sealsupport and a seal member supported by the seal support; the first endcap seal member having an inwardly radially directed seal surface and athickness between the seal support and the seal member surface thatvaries along the seal member surface.

In example embodiments, the radially directed seal surface of the firstend cap comprises a plurality of outwardly projecting and axiallyextending portions and a plurality of inwardly projecting and axiallyextending portions.

In example embodiments, the filter media is pleated media.

In example embodiments, the tubular section of filter media has a roundcross-section.

In a further aspect, a filter assembly is provided including a tubesheet having a filtered air aperture; a tri-pod yoke arrangement securedto the tube sheet; the yoke arrangement including a rod; a portion ofthe rod having a plurality of alternating outward radial sections andalternating inward radial sections; a filter element releasably securedto the tube sheet; the filter element having: (i) first and secondopposite end caps; the first end cap forming a seal with the tube sheet;(ii) a tubular section of filter media defining an interior volume incommunication with the filtered air aperture; and (iii) the second endcap having an integrated gasket with a seal member having a plurality ofcompressible alternating radial projections and alternating radialrecesses; the second end cap receiving the rod through the gasket inthat: the rod inward radial sections receive the seal member radialprojections; and the seal member radial recesses receive the rod outwardradial sections.

In example embodiments, there is a pivotable handle secured to a freeend of the rod.

In example embodiments, the tube sheet has a tube sheet seal memberalong the aperture; the tube sheet seal member having a plurality ofalternating outward radial portions and alternating inward radialportions; and the first end cap has a first filter element seal memberhaving a plurality of compressible alternating radial projections andalternating radial recesses; the first filter element seal memberforming a seal with the tube sheet seal member in that: the tube sheetseal member inward radial portions receive the first filter element sealmember radial projections; and the first filter element seal memberradial recesses receive the tube sheet seal member outward radialportions.

In another aspect, a filter element is provided comprising: a tubularsection of filter media; and

a first end cap secured to the filter media; the first end cap having aseal arrangement along an inner radial surface; the seal arrangementincluding a seal member having an inwardly radially directed sealsurface and a thickness that varies along the seal member surface; and asecond end cap secured to the filter media opposite of the first endcap; the second end cap being closed except for a seal-receiving openingin the center of the second end cap; the seal-receiving opening havingan outer diameter less than 20% of an outer diameter of the second endcap.

In example embodiments, the thickness of the seal member surface variesin a radial direction along the seal member surface.

In example embodiments, a length of the seal member surface is constantin an axial direction.

In some implementations, the seal member thickness varies by a minimumthickness and a maximum thickness, wherein the maximum thickness is atleast 1.1 times the minimum thickness.

The radially directed seal surface may comprise a plurality of outwardlyprojecting and axially extending portions and a plurality of inwardlyprojecting and axially extending portions.

In some examples, the plurality of outwardly projecting and axiallyextending portions and the plurality of inwardly projecting and axiallyextending portions comprise curved portions.

In example embodiments, the filter media is pleated media.

In example embodiments, the tubular section of filter media has a roundcross-section.

A variety of examples of desirable product features or methods are setforth in the description that follows, and in part, will be apparentfrom the description, or may be learned by practicing various aspects ofthis disclosure. The aspects of this disclosure may relate to individualfeatures, as well as combinations of features. It is to be understoodthat both the foregoing general description and the following detaileddescription are explanatory only, and are not restrictive of the claimedinventions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a gas turbine air inlet system usingfilter elements and assemblies constructed in accordance with principlesof this disclosure;

FIG. 2 is a perspective view of a filter assembly which can be utilizedin gas turbine filter systems, such as a system of FIG. 23, constructedin accordance with principles of this disclosure;

FIG. 3 is a perspective, exploded view of the assembly of FIG. 2;

FIG. 4 is another perspective, exploded view of the assembly of FIG. 2;

FIG. 5 is a side view of the filter assembly of FIG. 2;

FIG. 6 is a cross-sectional view of a first embodiment of the filterassembly of FIG. 2, the cross section being taken along the line A-A ofFIG. 5;

FIG. 7 is an enlarged perspective view of a portion of the filterassembly of FIG. 6 and rotated 90° from FIG. 6;

FIG. 8 is another perspective view of the portion of the assemblydepicted in FIG. 7;

FIG. 9 is a perspective view of another portion of the assembly of FIGS.7 and 8;

FIG. 10 is an enlarged, perspective view of one of the end caps of thefilter element used in the assembly of FIG. 6;

FIG. 11 is a cross-sectional view of the filter element used in theassembly of FIG. 6;

FIG. 12 is a perspective view of the seal plate shown in the assembly ofFIGS. 7 and 8;

FIG. 13 is another perspective view of the seal plate of FIG. 12;

FIG. 14 is a front view of the seal plate of FIG. 12;

FIG. 15 is a perspective view of an assembly cover used in the filterassembly of FIGS. 3 and 4;

FIG. 16 is a cross-sectional view of the assembly cover of FIG. 15;

FIG. 17 is an exploded, perspective view of a second embodiment of afilter assembly that can be used in the system of FIG. 1 or FIG. 23;

FIG. 18 is another perspective view of the assembly of FIG. 17;

FIG. 19 is a cross-sectional view of the filter assembly of FIGS. 17 and18, the cross section being taken along the line A-A of FIG. 5, in whichFIG. 5 has the same outward assembled appearance in both the assembly ofFIGS. 6 and 19;

FIG. 20 is a perspective view of an additional filter cartridge used inthe assembly of FIGS. 17-19;

FIG. 21 is a side view of the filter cartridge of FIG. 20;

FIG. 22 is a schematic, perspective view of filter media used in theadditional filter cartridge of FIGS. 20 and 21;

FIG. 23 is a schematic view of another gas turbine air inlet systemusing filter elements and assemblies constructed in accordance withprinciples of this disclosure;

FIG. 24 is a cross-sectional view of another filter assembly that can beused in the system of FIG. 1;

FIG. 25 is an enlarged cross-sectional view of an alternative filterassembly 100, varied from the assembly of FIGS. 17-19;

FIG. 26 is an enlarged cross-sectional view of another alternativefilter assembly 100, varied from the assembly of FIGS. 17-19;

FIG. 27 is an enlarged, schematic, cross-sectional view of a portion ofthe media type depicted in FIG. 22.

FIG. 28 includes schematic views of examples of various fluted mediadefinitions, for media of the type of FIGS. 22 and 27.

FIG. 29 is a schematic view of an example process for manufacturingmedia of the type of FIGS. 22, 27, and 28.

FIG. 30 is a schematic cross-sectional view of an optional end dart formedia flutes of the type of FIGS. 22 and 27-29.

FIG. 31 is a schematic perspective view of a coiled filter arrangementusable in a filter cartridge having features in accord with the presentdisclosure, and made with a strip of media for example in accord withFIG. 22.

FIG. 32 is a schematic perspective view of a stacked media packarrangement usable in a filter arrangement having selected features inaccord with the present disclosure and made from a strip of media forexample in accord with FIG. 22.

FIG. 33 is a schematic flow end view of a filter media pack using analternate media to the media of FIG. 22, and alternately usable inselected filter cartridges in accord with the present disclosure.

FIG. 34 is a schematic opposite flow end view to the view of FIG. 33.

FIG. 35 is a schematic cross-sectional view of the media pack of FIGS.33 and 34.

FIG. 36 is a schematic, fragmentary, cross-sectional view of a furtheralternate media type usable in a media pack of a filter cartridge havingfeatures in accord with the present disclosure.

FIG. 37 is a schematic, fragmentary cross-sectional view, of a firstvariation of the media type of FIG. 36.

FIG. 38 is a schematic fragmentary depiction of another usable flutedsheet/facing sheet combination in accord with the present disclosure.

FIG. 39 is a fragmentary second schematic view of the type of media inFIG. 38 shown in a media pack.

FIG. 40 is a schematic, fragmentary, plan view of still another mediavariation usable in arrangements according to the present disclosure.

FIG. 41 is a schematic view of another variation of usable media inaccord with the present disclosure.

FIG. 42 is a schematic depiction of another usable fluted sheet/facingsheet combination in accord with the present disclosure.

FIG. 43 is a perspective view of a portion of the usable flutedsheet/facing sheet combination depicted in FIG. 42.

FIG. 44 is a perspective view of another media variation useable inarrangements according to the present disclosure;

FIG. 45A is a schematic, perspective view of a portion of a supportsection of the filter media of FIG. 44, illustrated in a foldedconfiguration but expanded or separated for illustrative purposes;

FIG. 45B is a schematic, cross-sectional view of a portion of thesupport section of the filter media of FIG. 44, illustrated in a foldedconfiguration but expanded or separated for illustrative purposes;

FIG. 46 is a perspective view of another media variation useable inarrangements according to the present disclosure.

FIG. 47 is a perspective, exploded view of portions of the filterarrangement of FIG. 48;

FIG. 48 is a perspective view of a filter arrangement, constructed inaccordance with principles of this disclosure;

FIG. 49 is an end view of an alternative embodiment of a filterarrangement, constructed in accordance with principles of thisdisclosure;

FIG. 50 is a perspective view of the filter arrangement of FIG. 49;

FIG. 51 is a side elevational view of the filter arrangement of FIG. 49;

FIG. 52 is an end view of an alternative embodiment of a filterarrangement, constructed in accordance with principles of thisdisclosure;

FIG. 53 is an end view of an alternative embodiment of a filterarrangement, constructed in accordance with principles of thisdisclosure;

FIG. 54 is a perspective view of an alternative embodiment of a filterarrangement useable with a gas turbine air intake system;

FIG. 55 is a perspective, cross-sectional view of a portion of thefilter arrangement of FIG. 54;

FIG. 56 is an exploded, perspective and partially cross-sectional viewof portions of the filter arrangement of FIGS. 54 and 55;

FIG. 57 is a perspective view of a filter cartridge constructed toengage the seal plate of the tube sheet of FIG. 10;

FIG. 58 is an end view of the filter cartridge of FIG. 57;

FIG. 59 is a sectional view of the filter cartridge of FIG. 58 takenalong line 59-59;

FIG. 60 is a sectional view of the filter cartridge of FIG. 58 takenalong line 60-60; and

FIG. 61 is a sectional view of the end piece of the filter cartridge ofFIG. 60 taken along line 61-61.

DETAILED DESCRIPTION

A. System, FIGS. 1 and 23

FIGS. 1 and 23 depict two types of example gas turbine air intakesystems (filter systems) at 20. The system of FIG. 1 includes filterelements that are horizontally oriented, while the system of FIG. 23includes filter elements that are vertically oriented. Common parts willuse the same reference number.

In FIG. 1, the system 20 includes a chamber 21 having an air inlet side22 and an air outlet side 23. Air enters the chamber 21 through aplurality of vertically spaced inlet hoods 26 positioned along the airinlet side 22. The inlet hoods 26, although not required, function toprotect internal filters of the system 20 from the effects of rain, snowand sun. Also, the inlet hoods 26 are configured such that air enteringthe inlet hoods 26 is first directed in an upward direction indicated byarrow 27, and then deflected by deflector plates 28 in a downwarddirection indicated by arrow 29. The initial upward movement of aircauses some particulate material and moisture from the air stream tosettle or accumulate on lower regions 30 of the inlet hoods 26. Thesubsequent downward movement of air forces dust within the chamber 21downward toward a dust collection hopper 32 located at the bottom of thechamber 21. It should also be noted that air inlet side 22 may havevanes and other mechanical moisture separator inlets.

The chamber 21 of the system 20 is divided into upstream and downstreamvolumes 34 and 36 by a tube sheet 38 (also referred to also as partition38), which is oriented vertically in the FIG. 1 embodiment andhorizontally in the FIG. 23 embodiment. The upstream volume 34 generallyrepresents the “dirty air section” of the air cleaner system 20, whilethe downstream volume 36 generally represents the “clean air section” ofthe system 20. The tube sheet 38 defines a plurality of apertures 40 forallowing air to flow from the upstream volume 34 to the downstreamvolume 36. Each aperture 40 is covered by a filter pair 41, comprising acylindrical element 42 and a conical element 43. In other embodiments,the filter pair 41 can include two cylindrical elements; oralternatively, instead of a filter pair 41, there may be only a singleelement such as cylindrical element 42. In FIG. 1, the conical airfilter element 43, covers the aperture 40. Both elements 42 and 43 arelocated in the upstream volume 34 of the chamber. The filter elements42, 43 are arranged and configured such that air flowing from theupstream volume 34 to the downstream volume 36 passes through the filterelements 42, 43 prior to passing through the apertures 40.

Example filter elements 42 are described further below.

In general, during filtering, air is directed from the upstream volume34 through the filter elements 42. After being filtered, the air flowsthrough the tube sheet 38, via apertures 40, into the downstream cleanair volume 36. The clean air is then drawn out from the downstreamvolume 36 and into a gas turbine intake, not shown. The elements 42, inthe system 20 of FIG. 1, may be pulse cleaned to direct pulses of airbackward through the interior of the element 42 to dislodge material onan upstream portion of the elements 42. The pulse jet air cleaners canbe sequentially operated from the top to the bottom of the chamber 21 toeventually direct the dust particulate material blown from the filtersinto the lower hopper 32, for removal. In many air pulse jet cleaningapplications, a useful air pressure is generally within the range of 60to 1500 psi.

In the FIG. 23 embodiment, the tube sheet 38 is horizontal. In thesystem 20 of FIG. 23, each aperture 40 of the tube sheet 38 includes aventuri tube 46 for directing a pulse jet air of air mounted in thedownstream volume 36. Periodically, a pulse jet air cleaner is operatedto direct a pulse jet of air backwardly through the venturi tube 46 andinto the interior of the associated air filter element 42 to dislodgeparticular material trapped in or on the air filter element 42. The airto be filtered flows upwardly at inlet side 22, then through theelements 42, and then through the venturis 46, into the downstreamvolume 36, and exits through the outlet 48.

B. Example Assemblies, FIGS. 2-4, 17, 18 and 24

FIG. 2 is a perspective view of a filter assembly 100, which can be usedin the system 20 of FIG. 23. FIG. 24 shows a cross-sectional view offilter assembly 100, when filter pair 41 is used in the system ofFIG. 1. The filter assembly 100 can have many different embodiments. Oneexample embodiment is in FIGS. 3 and 4; while another example embodimentis in FIGS. 17 and 18; another example embodiment shown in FIG. 24;another example embodiment shown in FIGS. 54-56; and another exampleembodiment is in FIGS. 57-61. These filter assemblies 100 have commoncomponents, and the same reference numerals will be used to show thesame components (except for the embodiment of FIGS. 57-61, which usesdifferent reference numerals). A description of each component will notbe repeated for each embodiment, but will be incorporated by referencebased on the reference numeral.

In FIG. 2, the filter element 42 can be seen operably installed adjacentthe tube sheet 38. As will be explained further below, the element 42 issealed to seal plate 106, which is against the tube sheet 38. Alsovisible in FIG. 2 is a pivotable handle 102, which is part of a yokeassembly to removably secure the filter element 42 to the tube sheet 38.The handle 102 can be similar to the handle as described in U.S. Pat.No. 8,956,434 and U.S. 2017/0173512, each of which is incorporatedherein by reference in its entirety.

In the embodiments of FIGS. 3, 17, and 24, the aperture 40 (FIG. 1) inthe tube sheet 38 includes a tube sheet seal member 104. The tube sheetseal member 104 is along the aperture 40 and is attached to the tubesheet 38. It is releasably sealed to the filter element 42, as describedfurther below. Many examples are possible, and in the exampleembodiments of FIGS. 3, 17, and 24, the tube sheet seal member 104 ispart of seal plate 106. The seal plate 106 is described further belowand is used to attach the tube sheet seal member 104 to the tube sheet38.

Also visible in FIGS. 3 and 17 is a rod 108 which can be held by afixture 110, which is part of the yoke assembly for releasably holdingthe filter element 42 to the tube sheet 38. FIG. 24 includes a tri-podof legs 109, which is part of the yoke assembly for releasably holdingthe filter pair 41 to the tube sheet 38.

One difference between the assemblies 100 of FIGS. 3, 24 and FIG. 17 isthe assembly at the end of the filter element 42 opposite of the endthat connects to the tube sheet 38. In the FIGS. 3 and 24 assemblies,there is an assembly cover 112. The assembly cover 112, which isdescribed further below, covers the end of the filter element 42 andreceives the rod 108 (FIG. 3) or tri-pod legs 109 (FIG. 24) to allow theyoke assembly including the handle 102 to releasably secure the filterelement 42 (FIG. 3) or filter pair 41 (FIG. 24) to the tube sheet 38. Ascan also be seen in FIG. 3, there is a gasket washer 114, which engagesthe handle 102 and helps to releasably lock the filter element 42 to thetube sheet 38.

In the FIG. 17 embodiment, instead of an assembly cover 112, there is asecond or an additional filter cartridge 116. The additional filtercartridge 116 covers the open end of the filter element 42, which isopposite of the tube sheet 38, and provides for additional filtration.This is described further below. The additional filter cartridge 116allows for the rod 108 to pass therethrough and engage the handle 102and gasket washer 114.

C. Example Filter Element

An example embodiment of filter element 42 is now described further. Thefilter element 42 includes a tubular section of filter media 118. Thetubular section of media 118, in this embodiment, is cylindrical and hasa round cross-section. In other embodiments, the tubular shape could benon-cylindrical and have an oval or elliptical cross-section.

In this embodiment, the media 118 is pleated media 120. The pleatedmedia 120 can be made from cellulous. Many alternatives are possible.

The filter element 42 further includes a first end cap 122 and anopposite second end cap 124. The filter media 118 is secured to andextends between the first end cap 122 and second end cap 124.

The first end cap 122 is an open end cap in that it has an opening 126in communication with an interior volume 128 defined by the tubularsection of media 118.

While in some embodiments, the second end cap 124 could be a closed endcap, in the embodiment depicted, the second end cap 124 is an open endcap defining an opening 130. The opening 130 is in communication withthe interior volume 128. Further details about the first end cap 122 andsecond end cap 124 are discussed below.

An inner liner 132 extends between the first end cap 122 and second endcap 124. As will be described further below, the inner liner 132 helpsprevent the pleats of the pleated media 120 from collapsing and acts asa seal support. In alternate embodiments, no seal support is used, andin some of those alternate embodiments, no inner liner is used so thatthe element is inner-liner free.

In this embodiment, there is also an optional outer liner 134. The outerliner 134 is radially outside of the outer pleat tips of the pleatedmedia 120 and extends between the first end cap 122 and second end cap124. The outer liner 134 can also help support the pleats. Inalternative embodiments, there is no outer liner at all.

In FIGS. 2-5, it can be seen how, in this embodiment, there is anoptional winding bead 136 around the exterior of the pleated media 120.The winding bead 136 can include, for example, tape or a hot meltadhesive. The winding bead 136 will help to support the pleats andprevent pleat collapse.

In reference now to FIGS. 10 and 11, the first and second end caps 122,124 are further discussed. In the FIG. 24 embodiment, the conicalelement is illustrated as having first end cap 122′ and second end cap124′. Because these end caps 122′, 124′ are used with the conicallyshaped element 43, they vary in proportion to the end caps 122, 124. Itshould be understood, however, that the description of the end caps 122,124 generally applies to the end caps 122′, 124′ with the exception thatthe end caps 122′, 124′ are not identical to each other, and will varyin proportions. The end caps 122′, 124′ will form seals in the samegeneral way as the end caps 122, 124, as described next.

Each of the first end cap 122 and second end cap 124 has a sealarrangement 138, 140 along an inner radial surface 142, 144 of each ofthe end caps 122, 124. While many variations are possible, in thepreferred embodiment shown, the seal arrangements 138, 140 are identicalin that they have a same shape as the other. In this way, the filterelement 42 can be installed in the system 20 in any orientation. Thatis, in this embodiment, it does not matter whether the first end cap 122or the second end cap 124 is in connection with the tube sheet 38. (Asnoted above, this is not the case for the conical element 43, in whichthe end cap 122′ is the only end that connects to the tube sheet 38.)Both the first end cap 122 and second end cap 124 are attachable to thetube sheet 38. Likewise, at the end opposite of the tube sheet 38,either one of the first end cap 122 or second end cap 124 is attachableto the other components including, for example, the assembly cover 112(FIGS. 3 and 24) or the additional filter cartridge 116 (FIG. 17). InFIG. 24, the element 42 has end caps 122, 124 which are both attachableto assembly cover 112 or to the conical element 43.

Because in this embodiment the seal arrangements 138, 140 are identical,the same reference numerals and description will be used for each. Itshould be understood that in other arrangements, only one of the endcaps would have the seal arrangement, while the opposite end cap couldbe a closed end cap or have a different configuration.

The seal arrangements 138, 140 include seal support, in the form ofinner liner 132, and a seal member 146 supported by the seal support132. The seal member 146 has an inwardly radially directed seal surface148 and a thickness between the seal support 132 and the seal membersurface 148 that varies along the seal member surface 148. The thicknessof the seal member 146 can also be measured from the inner pleat tips ofthe pleated media 120. Example useable seal arrangements are describedin US 2017/0246571, incorporated herein by reference in its entirety.

As can be appreciated by reviewing FIG. 10, the thickness between theseal support 132 (or the inner pleat tips of the pleated media 120) andthe seal member 146 varies in a radial direction along the seal membersurface 148. The thickness between the seal support 132 and the sealmember surface 148 is constant in an axial direction. In other words,the length of the seal member surface 148 along the seal support 132 isrelatively constant in the axial direction, i.e., the directiongenerally parallel to the inner liner 132.

While many variations are possible, the seal member thickness varies bya minimum thickness and a maximum thickness. In general, the maximumthickness is at least 1.1 times the minimum thickness. Many variationsare possible. In embodiments in which the seal support is omitted, thethickness of the seal member 146 is measured from the inner pleat tipsof the pleated media 120.

The seal arrangements 138, 140 can be designed in accordance with thedescription of the seal arrangements provided in Patent Publication No.U.S. 2017/0246571, incorporated herein by reference.

In general, the radially directed seal surface 148 includes a pluralityof outwardly projecting and axially extending portions 150 and aplurality of inwardly projecting and axially extending portions 152.While many embodiments are possible, the plurality of outwardlyprojecting and axially extending portions 150 and the plurality ofinwardly projecting and axially extending portions 152 comprise curvedportions.

While many embodiments are possible, in the one shown, the plurality ofoutwardly projecting and axially extending portions 150 alternate withthe plurality of inwardly projecting and axially extending portions 152.As such, the seal member 146 forms a plurality of compressiblealternating radial projections 154 and alternating radial recesses 156.

There can be only a few or many portions 150, 152. For example, theradially directed seal surface 148 may comprise at least two of theradially outwardly projecting and axially extending portions 150alternating with at least two of the radially inwardly projecting andaxially extending portions 152 per inch along the seal support 132extending around a central axis 158 of the filter element 42. In manyinstances, radially directed seal surface 148 comprises greater than 20of the radially outwardly projecting and axially extending portions 150alternating with greater than 20 of the radially inwardly projecting andaxially extending portions 152.

In an alternative embodiment, the second end cap 124 is closed with theexception of a small opening in the center, which receives anon-removable or a removable seal. The first end cap 122 includes sealarrangement 138. The small opening in the center can have a diameterless than 20% of the outer diameter of the second end cap. In someembodiments, the small opening in the center can receive a sealingwasher around a shaft, used for retention, in which the seal is formedbetween the shaft and the hole. Alternatively, the seal could be moldedinto the hole.

D. Tube Sheet Components and Yoke Assembly

Attention is directed to FIGS. 7 and 8, which show an example embodimentof how the filter element 42 is releasably attached to the tube sheet38. As previously mentioned, the assembly 100 includes seal plate 106.Further views of the seal plate 106 are shown in FIGS. 12-14.

The seal plate 106 includes the tube sheet seal member 104 the tubesheet seal member 104 defines an inner opening 160 therethrough. Theopening 160 is in communication with the aperture 40 in the tube sheet38, when the seal plate 106 is operably mounted to the tube sheet 38.

In this embodiment, the seal plate 106 includes a collar 162 and a neck164. The collar 162 includes an outer rim 166 which is against andadjacent the tube sheet 38. The collar 162, in this embodiment, extendsgenerally along the tube sheet 38 and can be generally parallel to thetube sheet 38, although variations are possible.

The neck 164 projects axially from the collar 162 and circumscribes theopening 160. The tube sheet seal member 104 is generally along and canbe part of the neck 164. The neck 164 extends in an axial directionopposite of the direction that the rim 166 extends from the collar 162.

The tube sheet seal member 104 is shaped to releasably seal with theseal arrangements 138, 140. In this embodiment, the tube sheet sealmember 104 has a plurality of alternating outward radial portions 168and alternating inward radial portions 170. As can be seen in FIGS.12-14, there are greater than 20 outward radial portions 168 and inwardradial portions 170. The outward radial portions 168 and inward radialportions 170, in this embodiment, extend substantially a complete lengthof the neck 164.

When the filter element 42 is removably attached to the tube sheet 38,the seal member 146 forms a seal with the tube sheet seal member 104 inthat the tube sheet seal member 104 inward radial portions 170 receivethe first filter element seal member radial projections 154; and theseal member 146 having the radial recesses 156 receive the tube sheetseal member 104 outward radial portions 168. This connection helps toensure a good seal is formed, and ensure that the correct filter element42 is being installed within the filter assembly 100.

In reference again to FIGS. 7 and 8, the filter assembly 100 includes ayoke plate 172. Additional views of the yoke plate 172 can be seen inFIG. 9. The yoke plate 172 is secured to the tube sheet on the cleanside of the tube sheet 38, on an opposite side from where the filterelement 42 is secured. FIG. 9 omits the presence of the tube sheet fromthe drawing, to enhance clarity.

The yoke plate 172 defines an opening 174, which is generally coaxiallyaligned with the aperture 40 in the tube sheet 38 and opening 160 in theseal plate 106.

The yoke plate 172 includes a surrounding band 176, surrounding theopening 174. The band 176 generally lies flat and against the tube sheet138, although variations are possible.

The band 176 can include a plurality of holes 178. The holes 178accommodate fasteners, such as bolts 180. The bolts 180 extend through aportion of the venturi tube 46 and secure the venturi tube 46 to thetube sheet 38.

The yoke plate 172 includes a chord extending across the opening 174between edges of the band 176. In this example, the chord 182 extendsacross the geometric center of the opening 174, although there could bevariations in other embodiments. The chord 182 includes the fixture 110for removably holding the rod 108. As can be seen in FIG. 9, there is agasket washer 184, which is part of the fixture 110, for holding the rod108.

The rod 108 is secured to the tube sheet 38 with the gasket washer 108and the yoke plate 172. The rod 108 extends through the interior volume128 of the filter element 42 and through either the assembly cover 112or the additional filter cartridge 116, depending upon the embodiment.

The end of the rod 108 includes radial projections 186, 187 (FIGS. 3 and4). The radially projections 186, 187 engage with the handle 102, suchthat when the handle 102 is pivoted in the locked position (FIG. 2),with the grasping portion 188 (FIG. 2) pointing generally radiallyoutwardly, the filter element 42 is sealed to the tube sheet seal member104 through a radial seal. When the handle 102 is in a released positionwith the grasping portion 188 pointing generally in an axial direction,the projections 186, 187 on the rod 108 are not tightly engaged with thehandle 102, and the filter element 42 can be removed from the tube sheetseal member 104 and the tube sheet 38 by removing the handle 102 andremoving the gasket washer 114.

In the FIG. 24, embodiment, the cylindrical element 42 and conicalelement 43 are sealed together along connection 52 piece. The connectionpiece 52 can be shaped to be received by and form seals with end cap124′ and end cap 122; alternatively, the connection piece 52 can form anaxial insert between elements 42 and 43 to form an axial sealtherebetween.

E. Example Assembly Cover

As mentioned previously, in the embodiment of FIGS. 3 and 4, the filterassembly 100 includes assembly cover 112. Further views of the assemblycover 112 are shown in FIGS. 15 and 16.

Referring now to FIGS. 15 and 16, the assembly cover 112 includes asurrounding wall 190. The wall 190 extends from an end plate 192. Ingeneral, the wall 190 is perpendicular to the end plate 192. The wall190 is sized to extend into the opening 130 of the second end cap 124(or alternatively, into the opening 126 of the first end cap 122, whenthe filter element 42 is axially reversed).

The end plate 192 is sized to extend over and cover the axial end of thesecond end cap 124 (or the first end cap 122, when the element 42 isreversed).

The end plate 192 includes an aperture 194 in the center therethrough.The aperture 194 allows for passage of the rod 108.

In FIG. 16, it can be seen how the end plate 192 includes an outer mostbrim 196, which is generally planar and flat. The surrounding wall 190extends from an inside surface 198 of the brim 196.

Extending radially inwardly along the brim 196 and radially inwardly ofwhere the wall 190 extends, the end plate 192 includes a concave section200. The concave section 200 extends inwardly to be within thesurrounding wall 190. In the center of the concave section 200 is theaperture 194. Many embodiments are possible.

The assembly cover 112 includes a plurality alternating outward radialportions 202 and alternating inward radial portions 204. In theembodiment shown, the outward radial portions 202 and inward radialportions 204 are part of the surrounding wall 190. As such, the assemblycover 112 can be used to form a seal with the second end cap 124(alternatively, with the first end cap 122). A releasable seal can beformed between the element 42 and assembly cover 112 by having theinward radial portions 204 of the assembly cover 112 receive the sealmember radial projections 154; and the seal member radial recesses 156receive the outward radial portions 202 of the assembly cover 112.

F. Example Additional Filter Cartridge

As mentioned previously, in the embodiment of FIGS. 17-19, the assembly100 includes additional filter cartridge 116. Additional views of theadditional filter cartridge 116 are depicted in FIGS. 20 and 21.Alternative embodiments are shown in FIGS. 25 and 26.

The additional filter cartridge 116 is made from z-filter media 401. Thefilter media 401 can be used to form a “z-filter construction.” The term“z-filter construction” as used herein, is meant to include (but not belimited) a type of filter construction in which individual ones ofcorrugated, folded or otherwise formed filter flutes are used to define(typically in combination with facing media) sets of longitudinal,typically parallel, inlet and outlet filter flutes for fluid flowthrough the media. Some examples of z-filter media are provided in U.S.Pat. Nos. 5,820,646; 5,772,883; 5,902,364; 5,792,247; 5,895,574;6,210,469; 6,190,432; 6,350,291; 6,179,890; 6,235,195; Des. 399,944;Des. 428,128; Des. 396,098; Des. 398,046; and, Des. 437,401; each ofthese cited references being incorporated herein by reference.

One type of z-filter media, utilizes two specific media componentsjoined together, to form the media construction. The two components are:(1) a fluted (typically corrugated) media sheet or sheet section, and,(2) a facing media sheet or sheet section. The facing media sheet istypically non-corrugated, however it can be corrugated, for exampleperpendicularly to the flute direction as described in U.S. provisional60/543,804, filed Feb. 11, 2004, and published as PCT WO 05/077487 onAug. 25, 2005, incorporated herein by reference.

The fluted media section and facing media section can comprise separatematerials between one another. However, they can also be sections of thesingle media sheet folded to bring the facing media material intoappropriate juxtaposition with the fluted media portion of the media.

The fluted (typically corrugated) media sheet and the facing media sheetor sheet section together, are typically used to define media havingparallel flutes. In some instances, the fluted sheet and facing sheetare separate and then secured together and are then coiled, as a mediastrip, to form a z-filter media construction. Such arrangements aredescribed, for example, in U.S. Pat. Nos. 6,235,195 and 6,179,890, eachof which is incorporated herein by reference. In certain otherarrangements, some non-coiled sections or strips of fluted (typicallycorrugated) media secured to facing media, are stacked with one another,to create a filter construction. An example of this is described in FIG.11 of U.S. Pat. No. 5,820,646, incorporated herein by reference.

Herein, strips of material comprising fluted sheet (sheet of media withridges) secured to corrugated sheet, which are then assembled intostacks to form media packs, are sometimes referred to as “single facerstrips,” “single faced strips,” or as “single facer” or “single faced”media. The terms and variants thereof, are meant to refer to a fact thatone face, i.e., a single face, of the fluted (typically corrugated)sheet is faced by the facing sheet, in each strip.

Typically, coiling of a strip of the fluted sheet/facing sheet (i.e.,single facer) combination around itself, to create a coiled media pack,is conducted with the facing sheet directed outwardly. Some techniquesfor coiling are described in U.S. provisional application 60/467,521,filed May 2, 2003 and PCT Application US 04/07927, filed Mar. 17, 2004,now published as WO 04/082795, each of which is incorporated herein byreference. The resulting coiled arrangement generally has, as the outersurface of the media pack, a portion of the facing sheet, as a result.

The term “corrugated” used herein to refer to structure in media, isoften used to refer to a flute structure resulting from passing themedia between two corrugation rollers, i.e., into a nip or bite betweentwo rollers, each of which has surface features appropriate to causecorrugations in the resulting media. The term “corrugation” is however,not meant to be limited to such flutes, unless it is stated that theyresult from flutes that are by techniques involving passage of mediainto a bite between corrugation rollers. The term “corrugated” is meantto apply even if the media is further modified or deformed aftercorrugation, for example by the folding techniques described in PCT WO04/007054, and published Jan. 22, 2004, incorporated herein byreference.

Corrugated media is a specific form of fluted media. Fluted media ismedia which has individual flutes or ridges (for example formed bycorrugating or folding) extending thereacross.

Serviceable filter element or filter cartridge configurations utilizingz-filter media are sometimes referred to as “straight through flowconfigurations” or by variants thereof. In general, in this context whatis meant is that the serviceable filter elements or cartridges generallyhave an inlet flow end (or face) and an opposite exit flow end (orface), with flow entering and exiting the filter cartridge in generallythe same straight through direction. The term “serviceable” in thiscontext is meant to refer to a media containing filter cartridge that isperiodically removed and replaced from a corresponding fluid (e.g. air)cleaner. In some instances, each of the inlet flow end (or face) andoutlet flow end (or face) will be generally flat or planar, with the twoparallel to one another. However, variations from this, for examplenon-planar faces, are possible.

A straight through flow configuration (especially for a coiled orstacked media pack) is, for example, in contrast to serviceable filtercartridges such as cylindrical pleated filter cartridges of the typeshown in U.S. Pat. No. 6,039,778, incorporated herein by reference, inwhich the flow generally makes a substantial turn as its passes into andout of the media. That is, in a U.S. Pat. No. 6,039,778 filter, the flowenters the cylindrical filter cartridge through a cylindrical side, andthen turns to exit through an open end of the media (in forward-flowsystems). In a typical reverse-flow system, the flow enters theserviceable cylindrical cartridge through an open end of the media andthen turns to exit through a side of the cylindrical filter media. Anexample of such a reverse-flow system is shown in U.S. Pat. No.5,613,992, incorporated by reference herein.

The term “z-filter media construction” and variants thereof as usedherein, without more, is meant to include, but not necessarily belimited to, any or all of: a web of corrugated or otherwise fluted media(media having media ridges) secured to (facing) media, whether thesheets are separate or part of a single web, with appropriate sealing(closure) to allow for definition of inlet and outlet flutes; and/or amedia pack constructed or formed from such media into a threedimensional network of inlet and outlet flutes; and/or, a filtercartridge or construction including such a media pack.

In FIG. 22, an example of media 401 useable in z-filter media is shown.The media 401 is formed from a corrugated (fluted) sheet 403 and afacing sheet 404.

In general, the corrugated sheet 403, FIG. 22, is of a type generallycharacterized herein as having a regular, curved, wave pattern of flutesor corrugations 407. The term “wave pattern” in this context, is meantto refer to a flute or corrugated pattern of alternating troughs 407 band ridges 407 a. The term “regular” in this context is meant to referto the fact that the pairs of troughs and ridges (407 b, 407 a)alternate with generally the same repeating corrugation (or flute) shapeand size. (Also, typically in a regular configuration each trough 407 bis substantially an inverse of each ridge 407 a.) The term “regular” isthus meant to indicate that the corrugation (or flute) pattern comprisestroughs and ridges with each pair (comprising an adjacent trough andridge) repeating, without substantial modification in size and shape ofthe corrugations along at least 70% of the length of the flutes. Theterm “substantial” in this context, refers to a modification resultingfrom a change in the process or form used to create the corrugated orfluted sheet, as opposed to minor variations from the fact that themedia sheet 403 is flexible. With respect to the characterization of arepeating pattern, it is not meant that in any given filterconstruction, an equal number of ridges and troughs is necessarilypresent. The media 401 could be terminated, for example, between a paircomprising a ridge and a trough, or partially along a pair comprising aridge and a trough. (For example, in FIG. 22 the media 401 depicted infragmentary has eight complete ridges 407 a and seven complete troughs407 b.) Also, the opposite flute ends (ends of the troughs and ridges)may vary from one another. Such variations in ends are disregarded inthese definitions, unless specifically stated. That is, variations inthe ends of flutes are intended to be covered by the above definitions.

In the context of the characterization of a “curved” wave pattern ofcorrugations, the term “curved” is meant to refer to a corrugationpattern that is not the result of a folded or creased shape provided tothe media, but rather the apex 407 a of each ridge and the bottom 407 bof each trough is formed along a radiused curve. Although alternativesare possible, a typical radius for such z-filter media would be at least0.25 mm and typically would be not more than 3 mm. (Media that is notcurved, by the above definition, can also be useable.)

An additional characteristic of the particular regular, curved, wavepattern depicted in FIG. 22, for the corrugated sheet 403, is that atapproximately a midpoint 430 between each trough and each adjacentridge, along most of the length of the flutes 407, is located atransition region where the curvature inverts. For example, viewing backside or face 403 a, FIG. 22, trough 407 b is a concave region, and ridge407 a is a convex region. Of course when viewed toward front side orface 403 b, trough 407 b of side 403 a forms a ridge; and, ridge 407 aof face 403 a, forms a trough. (In some instances, region 430 can be astraight segment, instead of a point, with curvature inverting at endsof the straight segment 430.)

A characteristic of the particular regular, curved, wave patterncorrugated sheet 403 shown in FIG. 22, is that the individualcorrugations are generally straight. By “straight” in this context, itis meant that through at least 70% (typically at least 80%) of thelength between edges 408 and 409, the ridges 407 a and troughs 407 b donot change substantially in cross-section. The term “straight” inreference to corrugation pattern shown in FIG. 22, in part distinguishesthe pattern from the tapered flutes of corrugated media described inFIG. 1 of WO 97/40918 and PCT Publication WO 03/47722, published Jun.12, 2003, incorporated herein by reference. The tapered flutes of FIG. 1of WO 97/40918, for example, would be a curved wave pattern, but not a“regular” pattern, or a pattern of straight flutes, as the terms areused herein.

Referring to the present FIG. 22 and as referenced above, the media 401has first and second opposite edges 408 and 409. When the media 401 iscoiled and formed into a media pack, in general edge 409 will form aninlet end for the media pack and edge 408 an outlet end, although anopposite orientation is possible as discussed below with respect to FIG.24.

Adjacent edge 408 the sheets 403, 404 are sealed to one another, forexample by sealant, in this instance in the form of a sealant bead 410,sealing the corrugated (fluted) sheet 403 and the facing sheet 404together. Bead 410 will sometimes be referred to as a “single facer”bead, when it is applied as a bead between the corrugated sheet 403 andfacing sheet 404, to form the single facer or media strip 401. Sealantbead 410 seals closed individual flutes 411 adjacent edge 408, topassage of air therefrom.

Adjacent edge 409, is provided sealant, in this instance in the form ofa seal bead 414. Seal bead 414 generally closes flutes 415 to passage ofunfiltered fluid therein, adjacent edge 409. Bead 414 would typically beapplied as the media 401 is coiled about itself, with the corrugatedsheet 403 directed to the inside. Thus, bead 414 will form a sealbetween a back side 417 of facing sheet 404, and side 418 of thecorrugated sheet 403. The bead 414 will sometimes be referred to as a“winding bead” when it is applied as the strip 401 is coiled into acoiled media pack. If the media 401 were cut in strips and stacked,instead of coiled, bead 414 would be a “stacking bead.”

In some applications, the corrugated sheet 403 is also tacked to thefacing sheet 4 at various points along the flute length, as shown atlines 404 a.

Referring to FIG. 22, once the media 401 is incorporated into a mediapack, for example by coiling or stacking, it can be operated as follows.First, air in the direction of arrows 412, would enter open flutes 411adjacent end 409. Due to the closure at end 408, by bead 410, the airwould pass through the media shown by arrows 413. It could then exit themedia pack, by passage through open ends 415 a of the flutes 415,adjacent end 408 of the media pack. Of course operation could beconducted with air flow in the opposite direction, as discussed forexample with respect to FIG. 24. The point being that in typical airfilter applications, at one end or face of the media pack unfiltered airflow goes in, and at an opposite end or face the filtered air flow goesout, with no unfiltered air flow through the pack or between the faces.

For the particular arrangement shown herein in FIG. 22, the parallelcorrugations 7 a, 7 b are generally straight completely across themedia, from edge 708 to edge 709. Straight flutes or corrugations can bedeformed or folded at selected locations, especially at ends.Modifications at flute ends for closure are generally disregarded in theabove definitions of “regular,” “curved” and “wave pattern.”

Z-filter constructions which do not utilize straight, regular curvedwave pattern corrugation (flute) shapes are known. For example in Yamadaet al. U.S. Pat. No. 5,562,825 corrugation patterns which utilizesomewhat semicircular (in cross section) inlet flutes adjacent narrowV-shaped (with curved sides) exit flutes are shown (see FIGS. 1 and 3,of U.S. Pat. No. 5,562,825). In Matsumoto, et al. U.S. Pat. No.5,049,326 circular (in cross-section) or tubular flutes defined by onesheet having half tubes attached to another sheet having half tubes,with flat regions between the resulting parallel, straight, flutes areshown, see FIG. 2 of Matsumoto '326. In Ishii, et al. U.S. Pat. No.4,925,561 (FIG. 1) flutes folded to have a rectangular cross section areshown, in which the flutes taper along their lengths. In WO 97/40918(FIG. 1), flutes or parallel corrugations which have a curved, wavepatterns (from adjacent curved convex and concave troughs) but whichtaper along their lengths (and thus are not straight) are shown. Also,in WO 97/40918 flutes which have curved wave patterns, but withdifferent sized ridges and troughs, are shown.

In general, the filter media is a relatively flexible material,typically a non-woven fibrous material (of cellulose fibers, syntheticfibers or both) often including a resin therein, sometimes treated withadditional materials. Thus, it can be conformed or configured into thevarious corrugated patterns, without unacceptable media damage. Also, itcan be readily coiled or otherwise configured for use, again withoutunacceptable media damage. Of course, it must be of a nature such thatit will maintain the required corrugated configuration, during use.

In the corrugation process, an inelastic deformation is caused to themedia. This prevents the media from returning to its original shape.However, once the tension is released the flute or corrugations willtend to spring back, recovering only a portion of the stretch andbending that has occurred. The facing sheet is sometimes tacked to thefluted sheet, to inhibit this spring back in the corrugated sheet.

Also, typically, the media contains a resin. During the corrugationprocess, the media can be heated to above the glass transition point ofthe resin. When the resin then cools, it will help to maintain thefluted shapes.

The media of the corrugated sheet 403, facing sheet 404 or both, can beprovided with a fine fiber material on one or both sides thereof, forexample in accord with U.S. Pat. No. 6,673,136, incorporated herein byreference.

An issue with respect to z-filter constructions relates to closing ofthe individual flute ends. Typically a sealant or adhesive is provided,to accomplish the closure. As is apparent from the discussion above, intypical z-filter media, especially that which uses straight flutes asopposed to tapered flutes, large sealant surface areas (and volume) atboth the upstream end and the downstream end are needed. High qualityseals at these locations are critical to proper operation of the mediastructure that results. The high sealant volume and area, creates issueswith respect to this.

Attention is again directed to FIGS. 20 and 21. The filter cartridge 116includes a media pack 206 of straight flow through media, such asz-media 401. The media pack 206 includes a first flow face 208 and anopposite second flow face 210. The flutes 411, 415 (FIG. 22) extend in adirection between the opposite first and second flow faces 208, 210. Aside wall 212 extends between the first and second flow faces 208, 210.

In this embodiment, the first flow face 208 corresponds to an inlet flowface, while the second flow face 210 corresponds to an outlet flow face.

The filter cartridge 116 includes a band 214 around the side wall 212.In one example embodiment, the band 214 is circumscribing and againstthe side wall 212, although alternatives are possible. The band 214includes a plurality of alternating outward radial portions 216 andalternating inward radial portions 218.

When the additional filter cartridge 116 is received within the secondend cap 124 (alternatively, within the first end cap 122), it forms aseal with the seal member 146 of the end cap 122, 124 such that theinward radial portions 218 of the band 214 receive the seal memberradial projections 154; and the seal member radial recesses 156 receivethe outward radial portions 216 of the band 214. An alternative sealarrangement between the filter cartridge 116 and element 42 is discussedfurther below in connection with FIG. 26.

As can be seen in FIGS. 20 and 21, the band 214 is oriented between thefirst flow face 208 and second flow face 210. In this embodiment, theband 214 is also adjacent the first flow face 208. Many embodiments arepossible.

The band 214 can be part of an end piece 220. The end piece 220 has aplate 222 extending radially from the first flow face 208. The band 214extends axially from the plate 222 and along the side wall 212. In thisexample embodiment, the band 214 is generally perpendicular to the plate222. The plate 222 will extend over and cover an axial end of the secondend cap 124, when operably installed.

In an alternative embodiment of FIG. 25, the element 42 and additionalfilter cartridge 116 are molded together in a single continuous endpiece 240, so that they are one unitary element pair 242. In thisembodiment, only the element 42 first end cap 122 includes the sealarrangement 138.

The media pack 206 is preferably a coiled media pack. In thisembodiment, the media pack 206 defines a central, open channel 224extending between and through the first and second flow faces 208, 210.This channel 224 allows the rod 108 to extend through the filtercartridge 116 in order to engage the handle 102. See FIG. 19.

In this embodiment, the media pack 206 has a cross-sectional shape thatmatches the cross-sectional shape of the openings 126, 130 of the endcaps 122, 124. In this example, the shape is round.

The additional filter cartridge 116 allows for flow of unfiltered airthrough the first flow face 208. The media pack 206 removes particulate,and filtered air the flows through the second flow face 210 to reach theinterior volume 128 of the filter element 42. From there, the filteredair flows through the aperture 40 and the tube sheet 38, through theventuri tube 46, and into the downstream volume 36 (FIG. 1) of thesystem 20.

In general, the additional filter cartridge 116 helps to balance thefilter gradient through the assembly 100 and add life to both elements42, 116. Without the filter cartridge 116, the element 42 would load inthe region nearest the tube sheet 38, but when the filter cartridge 116is used, in some systems, the air will flow initially through theadditional filter cartridge 116 first before flowing through the pleatedmedia 120 of the element 42. This leads to a more balanced filtergradient through the pleated media 120 and lengthens the life of theelement 42.

In the FIG. 26 embodiment, instead of a seal being formed between theadditional filter cartridge 116 and filter element 42 at seal member146, the filter cartridge 116 has an end piece 250 secured to the secondflow face 210. The end piece 250 has an axially projecting ring 252,which extends axially in a direction away from a remaining portion ofthe cartridge 116. The ring 252 extend radially outwardly from sidewall212 of the cartridge 116 and is sized to fit snuggly around (e.g.,circumscribe) an outer diameter 125 of the end cap 124 to form areleasable radial seal 254 between and against an inside surface of thering 252 and the outer diameter 125 of the end cap 124 of the element42.

G. Example Operations and Methods

In general, air to be filtered flows into the system 20 under the hoods26 and into the upstream volume 34. From there, the filtered air flowsthrough the filter elements 42. The media 118 filters the air, and thefiltered air exits the filter elements 42 through the aperture 40 in thetube sheet 38 and then through the venturi tube 46. The filtered airenters the downstream volume 36, where it then flows to the downstreamequipment a gas turbine.

In embodiments that include the additional filter cartridge 116, if thefilter elements 42 become clogged, the unfiltered air will bypass thepleated media 120 and flow through the media pack 206 of the additionalfilter cartridge 116. The media pack 206 will filter the air, and thefiltered air will flow into the interior volume 128 of the element 42and then exit through the aperture 40 in the tube sheet 38.

Periodically, the system 20 will pulse clean the elements 42 by emittinga pulse of air through the venturi tube 46, where it will enter theinterior volume 128 and knock of or blow off any dust or debris that hascollected on the upstream side of the pleated media 120.

After a period of operation, the system 20 will require servicing. Toservice the system 120, the filter elements 42 will need to be removedand replaced with new filter elements 42. To do that, the filter element42 is released by pivoting the quick release handle 102 from a lockedposition (FIGS. 2 and 19) to an unlocked position, in which the handle102 is pivoted to extend axially. The gasket washer 114 and handle 102are removed from the rod 108. In the embodiment of FIGS. 3 and 4, theassembly cover 112 is removed, and then the filter element 42 is removedfrom the tube sheet 38. A new filter element 42 is provided. Inembodiments that have elements 42 with identical seal members 138, 140,either end of the filter element 42 is oriented toward the tube sheet38. The new filter element 42 is sealed against the tube sheet 38 bycreating a seal between the first (or second) end cap 122 and the tubesheet seal member 104. This is done by engaging the outward radialportions 168 and inward radial portions 170 of the tube sheet sealmember 104 with the radial recesses 156 and radial projections 154 ofthe seal member 146 of the filter element 42.

The rod 108 is extended through the aperture 194 of the assembly cover112, while the outward radial portions 202 and inner radial portions 204of the assembly cover form a seal with the radial recesses 156 andradial projections 154 of the seal member 146 of the second (or first)end cap 124 of the filter element 42. The gasket washer 114 and handle102 are then put in engagement with the rod 108, and the handle 102 ispivoted into the locked position of FIGS. 2 and 19 to secure the newfilter element 42 in place.

For the embodiment of FIGS. 17 and 18, instead of forming a seal withthe assembly cover 112, the filter element 42 forms a seal with theadditional filter cartridge 116. This is done by engaging the outwardradial portions 216 and inward radial portions 218 of the band 214 withthe radial recesses 156 and radial projections 154 of the seal member146 of the element 42. The rod 108 passes through the channel 224 andengages the gasket washer 114 and handle 102, in which the handle 102 ispivoted into the locked position to secure the element 42 to the tubesheet 38. In FIG. 26, the filter element 42 seals with the additionalfilter cartridge 116 at outer radial seal 254 along the outer diameter125 of the end cap 124.

H. Additional Example Arrangements, FIGS. 54-56

In addition to the arrangement described above, all of which whosedescriptions are incorporated here by reference, the following elementsand systems are provided. The following arrangements can have any of theend caps, seal arrangements, and other various features as waspreviously described. Those features are not again described here.

In FIGS. 54-56, an alternate system is shown at 300. The system 300includes a filter arrangement 301. The filter arrangement 301 can beembodied as a single element 42 (as described previously), or it can bean element pair 302 operably installed adjacent the tube sheet 38. Thefilter element pair 302 includes a cylindrical element 304 and a conicalelement 305, axially aligned and stacked end-to-end. Alternatively, theelement pair 302 can include two cylindrical elements.

Yoke assembly 306 (FIG. 56) releasably holds the filter arrangement 301to the tube sheet 38. The yoke assembly 306 includes tri-pod of legs109. Rod 108 extends from the leg tripod 109 at an end remote from thetube sheet 38. Pivotable handle 102, which is part of the yoke assembly306, is secured to the free end of the rod 108 and operates to removablysecure the filter arrangement 301 to the tube sheet 38. The handle 102can be similar to the handle as described in U.S. Pat. No. 8,956,434 andU.S. 2017/0173512, each of which is incorporated herein by reference inits entirety.

The filter element 304 has a first end cap 310 and an opposite secondend cap 312. In embodiments in which the filter arrangement 301 includesonly a single element (such as element 42), the first end cap 310 willform a seal with the tube sheet 38, and can include the seal arrangement138 described above in connection with FIGS. 4-15. In the embodimentshown, the first end cap 310 is against the non-tube sheet end of theelement 305. The tube sheet end 311 of the element 305 may include anyof the various seal arrangements described above in connection withFIGS. 4-15, such as seal arrangement 138. Alternatively, it may be astandard axial seal.

The second end cap 312 of the filter element 304 includes a center,integrated gasket 314. The gasket 314 is made from a soft material andincludes a seal member 316. The seal member 316 surrounds arod-receiving through-aperture 318, through which the rod 108 passes.

The seal member 316 has an inwardly radially directed seal surface 319and a thickness that varies along the seal member surface 319. Thethickness varies in a radial direction along the seal member surface319. It should be understood that the seal surface 319 surrounds thethrough-aperture 318.

In FIG. 56, the radially directed seal surface 319 can be seen toinclude a plurality of outwardly projecting projections 320 and aplurality of inwardly projecting recesses 322. These projections 320 andrecesses 322 can be curved. In this example, a length of the seal membersurface 319 is constant in an axial direction.

The second end cap 312 has a recessed section 330 projecting inwardlyinto the filter interior 332. The integrated gasket 314 is centered inthe recessed section 330.

In the example shown, the integrated gasket 314 has an outer diameterless than that of the outer diameter of the second end cap 312. Forexample, the diameter of the integrated gasket 314 is less than 50%,indeed less than 30%, and often less than 20% of an outer diameter ofthe second end cap 312.

In the system 300, a portion of the rod 108 has a plurality ofalternating outward radial sections 340 and alternating inward radialsections 342. The second end cap 312 receives the rod 108 throughaperture 318 in the gasket 314 in that: the rod inward radial sections342 receive the seal member radial projections 320; and the seal memberradial recesses 322 receive the rod outward radial sections 340.

The contact between the rod 108 and the gasket 314 helps to increase thecontact between the filter element gasket 314 and the rod 108 to ensuregood sealing over the entire life time of the filter element 304. Thenumber of projections 320 and recesses 322 can vary according to thesealing compression factor that is needed. A pressure washer can be usedto help spread the load of the clamping system onto the second end cap312 of the filter element 304.

I. Additional Example Arrangements, FIGS. 57-61

In addition to the arrangement described above, all of which whosedescriptions are incorporated here by reference, the following elementsand systems are provided. The following arrangements can have any of theend caps, seal arrangements, and other various features as waspreviously described. Those features are not again described here.

Now referring to FIGS. 57-61, a filter cartridge or element (e.g.,primary or main) is shown at reference number 2350. The filter cartridge2350 as shown includes a first end piece (e.g., cap) 2352, a second endpiece (e.g., cap) 2354, filter media 2356, and a liner 2358. The filtermedia 2356 includes a first end 2356 a and a second end 2356 b. Ingeneral, the filter media first end 2356 a can be embedded in the firstend cap 2352, and the filter media second end 2356 b can be embedded inthe second end cap 2354. In addition, the liner 2358 includes a linerfirst end 2358 a and a liner second end 2358 b. The liner first end 2358a can also be embedded in the first end cap 2352, and the liner secondend 2358 b can be embedded in the second end cap 2354. In addition, thefilter media 2256 can be provided as supported by the liner 2258. Thefilter media 2256 can be provided as cylindrical or conical pleatedmedia, or as any other type of media configuration that provides thefilter cartridge 2350 with a central open volume 2360.

Now referring to FIGS. 60-61, the first end piece (e.g., cap) 2352 isshown in detail. The first end cap 2352 includes a central open volume2362 that is in communication with the filter element central openvolume 2360. Accordingly, the first end cap 2352 can be characterized asan open end cap 364. The second end cap 2354 can also be an open endcap.

The filter element 2350 can be used in, for example, the system 20 ofFIG. 1 or 23. The seal members 138, 140, as characterized above, arefurther defined below, and this further definition can apply to any ofthe previously described seal members 138, 140.

The open end cap 2364 includes a first end 2367, a second end 2369, andan internal surface 2370 extending between the first end 2367 and thesecond end 2369. The internal surface 2370 forms the central open volume2362, and can be constructed to engage and seal against the tube sheetseal member 104 (FIGS. 12-14) having a wavy wall. The internal surface2370 can form an internally directed radial seal.

The internal surface 2370 as shown includes a lead in region 2372, anoptional peripherally uniform radial seal region 2378, a transitionregion 2374, and a peripherally non-uniform radial seal region 2376. Theoptional peripherally uniform seal radial seal region 2378 can beomitted from the filter element 2350, and is provided in the event it isdesirable for the filter element 2350 to fit both a filter cartridgeseal surface that can be characterized as a wavy wall tube sheet sealmember and a prior art air tube sheet seal member having a peripherallyuniform seal surface about an axis X.

The lead in region 2372, the transition region 2374, and theperipherally non-uniform radial seal region 2376 can be characterized ashaving a plurality of radially outwardly projecting and axiallyextending portions 2390 alternating with a plurality of radiallyinwardly projecting and axially extending portions 2392. These portions2390 and 2392 can be provided extending axially along each of regions2372, 2374, and 2376 and not along region 2378 if region 2378 ispresent. The radially outwardly projecting and axially extendingportions 2390 can be characterized as troughs 2394, and the and theradially inwardly projecting and axially extending portions 2392 can becharacterized as peaks or ridges 2396. The lobes 2400 formed by thepeaks 2396 between adjacent troughs 2394 can be provided so that theyfit into the corresponding troughs (inward radial portions) 170 in thetube sheet seal member 104 (FIGS. 12-14). Similarly, the troughs 2394are provided so that they receive the peaks (outward radial portions)168 in the tube sheet seal member 104. It should be appreciated that thereference to “outwardly” and “inwardly” refer to a direction either awayfrom or toward the central axis X. Thus, the outwardly projecting andaxially extending portions 2390 can be referred to as troughs 2394, andthe inwardly projecting and axially extending portions 2392 can bereferred to as peaks 2396. The size and shape of the troughs 2394 andpeaks 2396 can be altered and adjusted throughout the lead in region2372, the transition region 2374, and the radially seal region 2376 inorder to ease the insertion of the filter element 2350 onto the tubesheet seal member 104.

The radial seal region 2376 includes a wavy wall seal member surface2398 that also includes a plurality of lobes 2400. The wavy wall sealmember surface can be characterized in terms of “pitch” which is thedistance from peak to adjacent peak of the lobes 2400. In the case ofthe wavy wall seal member surface 2376, the pitch can be defined as thedistance between adjacent peaks. Alternatively, the pitch can be definedas the distance between the adjacent troughs. The wavy wall seal membersurface 2376 can be characterized as having a pitch that allows theservice provider (installer of the filter element) with a degree ofindexing that allows the service provider to correctly index the filterelement within the housing without having to re-grip the filter element.As the filter cartridge 2350 is introduced into the wavy tube sheet sealmember, the lead in region 2372 engages the wavy wall of the tube sheetseal member 104 thereby indexing the filter cartridge 2350 into thecorrect orientation for further axial insertion. The peripherallyuniform radial seal surface 2378, if present, engages the wavy wall ofthe tube sheet seal member 104 with continued axial insertion. Furtheraxial insertion results in the transition region 2374 engaging the wavywall to help further orient the filter cartridge 2350 and ease thetransition to the radial seal region 2376 engaging the wavy wall of thetube sheet seal member 104 where a radially directed seal is created.

It should be appreciated that for the filter cartridge 2350, theperipherally non-uniform radial seal surface 2376 and the peripherallyuniform radial seal surface 2378 (if present) are recessed from thefirst end 2367 of the open end cap 2364. Furthermore, the seal surfaces2376 and 2378 can be characterized as provided inside of the filtermedia 2356. In addition, by recessing the seal surfaces 2376 and 2378from the first end 2367, the seal surfaces 2376 and 2378 are protectedfrom dust or debris when the filter cartridge 2350 is set on a dirtysurface. For example, the seal surfaces 2376 and 2378 can be axiallyrecessed at least about 1 millimeter from the first end 2367.

In some embodiments, the second end cap 2354 can have an identicalconstruction as the first end cap 2356 as characterized above.

II. Additional Media Configurations

A. Introduction

Principles according to the present disclosure relate to interactionsbetween filter cartridges and air cleaner systems, in advantageousmanners to achieve certain, selected, desired results discussed below.The filter cartridge would generally include a filter media therein,through which air and other gases pass, during a filtering operation.The media can be of a variety of types and configurations, and can bemade from using a variety of materials. For example, pleated mediaarrangements can be used in cartridges according to the principles ofthe present disclosure, as discussed below.

The principles are particularly well adapted for use in situations inwhich the media is quite deep in extension between the inlet and outletends of the cartridge, but alternatives are possible. Also, theprinciples are often used in cartridges having relatively largecross-dimension sizes. With such arrangements, alternate media types topleated media will often be desired.

In this section, examples of some media arrangements that are usablewith the techniques described herein are provided. It will beunderstood, however, that a variety of alternate media types can beused. The choice of media type is generally one of preference for:availability; function in a given situation of application, ease ofmanufacturability, etc. and the choice is not necessarily specificallyrelated to the overall function of selected ones of various filtercartridge/air cleaner interaction features characterized herein.

Media pack arrangements using filter media having media ridges (flutes)secured to facing media is described above with respect to FIG. 22.

Attention is now directed to FIG. 27, in which z-filter media; i.e., az-filter media construction 500, utilizing a regular, curved, wavepattern corrugated sheet 503, and a non-corrugated flat sheet 504, i.e.,a single facer strip is schematically depicted. The distance D1, betweenpoints 506 and 507, defines the extension of flat media 504 in region502 underneath a given corrugated flute 508. The length D2 of thearcuate media for the corrugated flute 508, over the same distance D1 isof course larger than D1, due to the shape of the corrugated flute 508.For a typical regular shaped media used in fluted filter applications,the linear length D2 of the media 508 between points 506 and 507 willoften be at least 1.2 times D1. Typically, D2 would be within a range of1.2-2.0 times D1, inclusive. One particularly convenient arrangement forair filters has a configuration in which D2 is about 1.25-1.35×D1. Suchmedia has, for example, been used commercially in Donaldson Powercore™Z-filter arrangements. Another potentially convenient size would be onein which D2 is about 1.4-1.6 times D1. Herein the ratio D2/D1 willsometimes be characterized as the flute/flat ratio or media draw for thecorrugated media.

In the corrugated cardboard industry, various standard flutes have beendefined. For example the standard E flute, standard X flute, standard Bflute, standard C flute and standard A flute. FIG. 3, attached, incombination with Table A below provides definitions of these flutes.

Donaldson Company, Inc., (DCI) the assignee of the present disclosure,has used variations of the standard A and standard B flutes, in avariety of z-filter arrangements. These flutes are also defined in TableA and FIG. 28.

TABLE A (Flute definitions for FIG. 3) DCI A Flute: Flute/flat = 1.52:1;The Radii (R) are as follows: R1000 = .0675 inch (1.715 mm); R1001 =.0581 inch (1.476 mm); R1002 = .0575 inch (1.461 mm); R1003 = .0681 inch(1.730 mm); DCI B Flute: Flute/flat = 1.32:1; The Radii (R) are asfollows: R1004 = .0600 inch (1.524 mm); R1005 = .0520 inch (1.321 mm);R1006 = .0500 inch (1.270 mm); R1007 = .0620 inch (1.575 mm); Std. EFlute: Flute/flat = 1.24:1; The Radii (R) are as follows: R1008 = .0200inch (.508 mm); R1009 = .0300 inch (.762 mm); R1010 = .0100 inch (.254mm); R1011 = .0400 inch (1.016 mm); Std. X Flute: Flute/flat = 1.29:1;The Radii (R) are as follows: R1012 = .0250 inch (.635 mm); R1013 =.0150 inch (.381 mm); Std. B Flute: Flute/flat = 1.29:1; The Radii (R)are as follows: R1014 = .0410 inch (1.041 mm); R1015 = .0310 inch (.7874mm); R1016 = .0310 inch (.7874 mm); Std. C Flute: Flute/flat = 1.46:1;The Radii (R) are as follows: R1017 = .0720 inch (1.829 mm); R1018 =.0620 inch (1.575 mm); Std. A Flute: Flute/flat = 1.53:1; The Radii (R)are as follows: R1019 = .0720 inch (1.829 mm); R1020 = .0620 inch (1.575mm).

Of course other, standard, flutes definitions from the corrugated boxindustry are known.

In general, standard flute configurations from the corrugated boxindustry can be used to define corrugation shapes or approximatecorrugation shapes for corrugated media. Comparisons above between theDCI A flute and DCI B flute, and the corrugation industry standard A andstandard B flutes, indicate some convenient variations.

It is noted that alternative flute definitions such as thosecharacterized in U.S. Ser. No. 12/215,718, filed Jun. 26, 2008; andpublished as US 2009/0127211; U.S. Ser. No. 12/012,785, filed Feb. 4,2008 and published as US 2008/0282890; and/or U.S. Ser. No. 12/537,069published as US 2010/0032365 can be used, with air cleaner features ascharacterized herein below. The complete disclosures of each of US2009/0127211, US 2008/0282890 and US 2010/0032365 are incorporatedherein by reference.

Another media variation comprising fluted media with facing mediasecured thereto, can be used in arrangements according to the presentdisclosure, in either a stacked or coiled form, is described in US2014/0208705 A1, owned by Baldwin Filters, Inc., published Jul. 31,2014, and incorporated herein by reference.

B. Manufacture of Media Pack Configurations Including the Media of FIGS.22, 27 & 28, See FIGS. 29-32

In FIG. 29, one example of a manufacturing process for making a mediastrip (single facer) corresponding to strip 1, FIG. 22 is shown. Ingeneral, facing sheet 510 and the fluted (corrugated) sheet 512 havingflutes 514 are brought together to form a media web 515, with anadhesive bead located therebetween at 516. The adhesive bead 516 willform a single facer bead 414, FIG. 22. An optional darting processoccurs at station 518 to form center darted section 520 located mid-web.The z-filter media or Z-media strip 522 can be cut or slit at 523 alongthe bead 516 to create two pieces or strips 524, 525 of z-filter media522, each of which has an edge with a strip of sealant (single facerbead) extending between the corrugating and facing sheet. Of course, ifthe optional darting process is used, the edge with a strip of sealant(single facer bead) would also have a set of flutes darted at thislocation.

Techniques for conducting a process as characterized with respect toFIG. 29 are described in PCT WO 04/007054, published Jan. 22, 2004incorporated herein by reference.

Still in reference to FIG. 29, before the z-filter media 522 is putthrough the darting station 518 and eventually slit at 523, it must beformed. In the schematic shown in FIG. 29, this is done by passing asheet of filter media 526 through a pair of corrugation rollers 528,529. In the schematic shown in FIG. 29, the sheet of filter media 526 isunrolled from a roll 530, wound around tension rollers 532, and thenpassed through a nip or bite 534 between the corrugation rollers 528,529. The corrugation rollers 528, 529 have teeth 536 that will give thegeneral desired shape of the corrugations after the flat sheet 526passes through the nip 534. After passing through the nip 534, the sheet526 becomes corrugated across the machine direction and is referenced at512 as the corrugated sheet. The corrugated sheet 512 is then secured tofacing sheet 510. (The corrugation process may involve heating themedia, in some instances.)

Still in reference to FIG. 29, the process also shows the facing sheet510 being routed to the darting process station 518. The facing sheet510 is depicted as being stored on a roll 106 and then directed to thecorrugated sheet 512 to form the Z-media 522. The corrugated sheet 512and the facing sheet 510 would typically be secured together by adhesiveor by other means (for example by sonic welding).

Referring to FIG. 29, an adhesive line 516 is shown used to securecorrugated sheet 512 and facing sheet 510 together, as the sealant bead.Alternatively, the sealant bead for forming the facing bead could beapplied as shown as 516 a. If the sealant is applied at 516 a, it may bedesirable to put a gap in the corrugation roller 529, and possibly inboth corrugation rollers 528, 529, to accommodate the bead 516 a.

Of course the equipment of FIG. 29 can be modified to provide for thetack beads 20, FIG. 22, if desired.

The type of corrugation provided to the corrugated media is a matter ofchoice, and will be dictated by the corrugation or corrugation teeth ofthe corrugation rollers 528, 529. One useful corrugation pattern will bea regular curved wave pattern corrugation, of straight flutes or ridges,as defined herein above. A typical regular curved wave pattern used,would be one in which the distance D2, as defined above, in a corrugatedpattern is at least 1.2 times the distance D1 as defined above. Inexample applications, typically D2=1.25−1.35×D1, although alternativesare possible. In some instances the techniques may be applied withcurved wave patterns that are not “regular,” including, for example,ones that do not use straight flutes. Also, variations from the curvedwave patterns shown, are possible.

As described, the process shown in FIG. 29 can be used to create thecenter darted section 520. FIG. 30 shows, in cross-section, one of theflutes 514 after darting and slitting.

A fold arrangement 538 can be seen to form a darted flute 540 with fourcreases 541 a, 541 b, 541 c, 541 d. The fold arrangement 538 includes aflat first layer or portion 542 that is secured to the facing sheet 510.A second layer or portion 544 is shown pressed against the first layeror portion 542. The second layer or portion 544 is preferably formedfrom folding opposite outer ends 546, 547 of the first layer or portion542.

Still referring to FIG. 30, two of the folds or creases 541 a, 541 bwill generally be referred to herein as “upper, inwardly directed” foldsor creases. The term “upper” in this context is meant to indicate thatthe creases lie on an upper portion of the entire fold 540, when thefold 540 is viewed in the orientation of FIG. 30. The term “inwardlydirected” is meant to refer to the fact that the fold line or creaseline of each crease 541 a, 541 b, is directed toward the other.

In FIG. 30, creases 541 c, 541 d, will generally be referred to hereinas “lower, outwardly directed” creases. The term “lower” in this contextrefers to the fact that the creases 541 c, 541 d are not located on thetop as are creases 541 a, 541 b, in the orientation of FIG. 30. The term“outwardly directed” is meant to indicate that the fold lines of thecreases 541 c, 541 d are directed away from one another.

The terms “upper” and “lower” as used in this context are meantspecifically to refer to the fold 540, when viewed from the orientationof FIG. 30. That is, they are not meant to be otherwise indicative ofdirection when the fold 540 is oriented in an actual product for use.

Based upon these characterizations and review of FIG. 30, it can be seenthat a regular fold arrangement 538 according to FIG. 30 in thisdisclosure is one which includes at least two “upper, inwardly directed,creases.” These inwardly directed creases are unique and help provide anoverall arrangement in which the folding does not cause a significantencroachment on adjacent flutes.

A third layer or portion 548 can also be seen pressed against the secondlayer or portion 544. The third layer or portion 548 is formed byfolding from opposite inner ends 550, 551 of the third layer 548.

Another way of viewing the fold arrangement 538 is in reference to thegeometry of alternating ridges and troughs of the corrugated sheet 512.The first layer or portion 542 is formed from an inverted ridge. Thesecond layer or portion 544 corresponds to a double peak (afterinverting the ridge) that is folded toward, and in preferredarrangements, folded against the inverted ridge.

Techniques for providing the optional dart described in connection withFIG. 30, in a preferred manner, are described in PCT WO 04/007054,incorporated herein by reference. Techniques for coiling the media, withapplication of the winding bead, are described in PCT application US04/07927, filed Mar. 17, 2004 and published as WO 04/082795 andincorporated herein by reference.

Alternate approaches to darting the fluted ends closed are possible.Such approaches can involve, for example: darting which is not centeredin each flute; and, rolling, pressing or folding over the variousflutes. In general, darting involves folding or otherwise manipulatingmedia adjacent to fluted end, to accomplish a compressed, closed, state.

Techniques described herein are particularly well adapted for use inmedia packs that result from a step of coiling a single sheet comprisinga corrugated sheet/facing sheet combination, i.e., a “single facer”strip. However, they can also be made into stacked arrangements.

Coiled media or media pack arrangements can be provided with a varietyof peripheral perimeter definitions. In this context the term“peripheral, perimeter definition” and variants thereof, is meant torefer to the outside perimeter shape defined, looking at either theinlet end or the outlet end of the media or media pack. Typical shapesare circular as described in PCT WO 04/007054. Other useable shapes areobround, some examples of obround being oval shape. In general ovalshapes have opposite curved ends attached by a pair of opposite sides.In some oval shapes, the opposite sides are also curved. In other ovalshapes, sometimes called racetrack shapes, the opposite sides aregenerally straight. Racetrack shapes are described for example in PCT WO04/007054, and PCT application US 04/07927, published as WO 04/082795,each of which is incorporated herein by reference.

Another way of describing the peripheral or perimeter shape is bydefining the perimeter resulting from taking a cross-section through themedia pack in a direction orthogonal to the winding access of the coil.

Opposite flow ends or flow faces of the media or media pack can beprovided with a variety of different definitions. In many arrangements,the ends or end faces are generally flat (planer) and perpendicular toone another. In other arrangements, one or both of the end faces includetapered, for example, stepped, portions which can either be defined toproject axially outwardly from an axial end of the side wall of themedia pack; or, to project axially inwardly from an end of the side wallof the media pack.

The flute seals (for example from the single facer bead, winding bead orstacking bead) can be formed from a variety of materials. In variousones of the cited and incorporated references, hot melt or polyurethaneseals are described as possible for various applications.

In FIG. 31, a coiled media pack (or coiled media) 550 constructed bycoiling a single strip of single faced media is depicted, generally. Theparticular coiled media pack depicted is an oval media pack 550 a,specifically a racetrack shaped media pack 551. The tail end of themedia, at the outside of the media pack 550 is shown at 551 x. It willbe typical to terminate that tail end along straight section of themedia pack 550 for convenience and sealing. Typically, a hot melt sealbead or seal bead is positioned along that tail end to ensure sealing.In the media pack 550, the opposite flow (end) faces are designated at552, 553. One would be an inlet flow face, the other an outlet flowface.

In FIG. 32, there is (schematically) shown a step of forming stackedz-filter media (or media pack) from strips of z-filter media, each stripbeing a fluted sheet secured to a facing sheet. Referring to FIG. 6,single facer strip 560 is being shown added to a stack 561 of strips 562analogous to strip 560. Strip 560 can be cut from either of strips 524,525, FIG. 29. At 563, FIG. 31, application of a stacking bead 564 isshown, between each layer corresponding to a strip 560, 562 at anopposite edge from the single facer bead or seal. (Stacking can also bedone with each layer being added to the bottom of the stack, as opposedto the top.)

Referring to FIG. 32, each strip 560, 562 has front and rear edges 565,566 and opposite side edges 568 a, 568 b. Inlet and outlet flutes of thecorrugated sheet/facing sheet combination comprising each strip 560, 562generally extend between the front and rear edges 207, 566, and parallelto side edges 568 a, 568 b.

Still referring to FIG. 32, in the media or media pack 561 being formed,opposite flow faces are indicated at 570, 571. The selection of whichone of faces 570, 571 is the inlet end face and which is the outlet endface, during filtering, is a matter of choice. In some instances thestacking bead 564 is positioned adjacent the upstream or inlet face 571;in others the opposite is true. The flow faces 570, 571, extend betweenopposite side faces 572, 573.

The stacked media configuration or pack 561 shown being formed in FIG.32, is sometimes referred to herein as a “blocked” stacked media pack.The term “blocked” in this context, is an indication that thearrangement is formed to a rectangular block in which all faces are 90°relative to all adjoining wall faces. For example, in some instances thestack can be created with each strip 560 being slightly offset fromalignment with an adjacent strip, to create a parallelogram or slantedblock shape, with the inlet face and outlet face parallel to oneanother, but not perpendicular to upper and bottom surfaces.

In some instances, the media or media pack will be referenced as havinga parallelogram shape in any cross-section, meaning that any twoopposite side faces extend generally parallel to one another.

It is noted that a blocked, stacked arrangement corresponding to FIG. 32is described in the prior art of U.S. Pat. No. 5,820,646, incorporatedherein by reference. It is also noted that stacked arrangements aredescribed in U.S. Pat. Nos. 5,772,883; 5,792,247; U.S. Provisional60/457,255 filed Mar. 25, 2003; and U.S. Ser. No. 10/731,564 filed Dec.8, 2003 and published as 2004/0187689. Each of these latter referencesis incorporated herein by reference. It is noted that a stackedarrangement shown in U.S. Ser. No. 10/731,504, published as 2005/0130508is a slanted stacked arrangement.

It is also noted that, in some instances, more than one stack can beincorporated into a single media pack. Also, in some instances, thestack can be generated with one or more flow faces that have a recesstherein, for example, as shown in U.S. Pat. No. 7,625,419 incorporatedherein by reference.

C. Selected Media or Media Pack Arrangements Comprising Multiple SpacedCoils of Fluted Media; FIGS. 33-35

Alternate types of media arrangements or packs that involve flutesbetween opposite ends extending between can be used with selectedprinciples according to the present disclosure. An example of suchalternate media arrangement or pack is depicted in FIGS. 33-35. Themedia of FIGS. 33-35 is analogous to one depicted and described in DE 202008 017 059 U1; and as can sometimes found in arrangements availableunder the mark “IQORON” from Mann & Hummel.

Referring to FIG. 33, the media or media pack is indicated generally at580. The media or media pack 580 comprises a first outer pleated(ridged) media loop 581 and a second, inner, pleated (ridged) media loop582, each with pleat tips (or ridges) extending between opposite flowends. The view of FIG. 33 is toward a media pack (flow) end 585. The end585 depicted, can be an inlet (flow) end or an outlet (flow) end,depending on selected flow direction. For many arrangements usingprinciples characterized having the media pack 580 would be configuredin a filter cartridge such that end 585 is an inlet flow end.

Still referring to FIG. 33, the outer pleated (ridged) media loop 581 isconfigured in an oval shape, though alternatives are possible. At 590, apleat end closure, for example molded in place, is depicted closing endsof the pleats or ridges 581 at media pack end 585.

Pleats, or ridges 582 (and the related pleat tips) are positionedsurrounded by and spaced from loop 581, and thus pleated media loop 582is also depicted in a somewhat oval configuration. In this instance,ends 582 e of individual pleats or ridges 582 p in a loop 582 are sealedclosed. Also, loop 582 surrounds the center 582 c that is closed by acenter strip 583 of material, typically molded-in-place.

During filtering, when end 585 is an inlet flow end, air enters gap 595between the two loops of media 581, 582. The air then flows eitherthrough loop 581 or loop 582, as it moves through the media pack 580,with filtering.

In the example depicted, loop 581 is configured slanting inwardly towardloop 582, in extension away from end 585. Also spacers 596 are shownsupporting a centering ring 597 that surrounds an end of the loop 582,for structural integrity.

In FIG. 34, an end 586 of the cartridge 580, opposite end 585 isviewable. Here, an interior of loop 582 can be seen, surrounding an opengas flow region 598. When air is directed through cartridge 580 in ageneral direction toward end 586 and away from end 585, the portion ofthe air that passes through loop 582 will enter central region 598 andexit therefrom at end 586. Of course air that has entered media loop581, FIG. 33 during filtering would generally pass around (over) anouter perimeter 586 p of end 586.

In FIG. 35 a schematic cross sectional view of cartridge 580 isprovided. Selected identified and described features are indicated bylike reference numerals

It will be understood from a review of FIGS. 33-35, the abovedescription, that the cartridge 580 described, is generally a cartridgewhich has media tips extending in a longitudinal direction betweenopposite flow ends 585, 586.

In the arrangement of FIGS. 33-35, the media pack 580 is depicted withan oval, in particular racetrack, shaped perimeter. It is depicted inthis manner, since the air filter cartridges in many examples below alsohave an oval or racetrack shaped configuration. However, the principlescan be embodied in a variety of alternate peripheral shapes.

D. Other Media Variations, FIGS. 36-43

Herein, in FIGS. 36-43, some schematic, fragmentary, cross-sectionalviews are provided of still further alternate variations of media typesthat can be used in selected applications of the principlescharacterized herein. Certain examples are described in U.S. Ser. No.62/077,749, filed Nov. 10, 2014 and owned by the Assignee of the presentdisclosure, Donaldson Company, Inc. In general, each of the arrangementsof FIGS. 36-43 represents a media type that can be stacked or coiledinto an arrangement that has opposite inlet and outlet flow ends (orfaces), with straight through flow.

In FIG. 36, an example media arrangement 601 from U.S. Ser. No.62/077,749 (2658) is depicted, in which an embossed sheet 602 is securedto a non-embossed sheet 603, then stacked and coiled into a media pack,with seals along opposite edges of the type previously described forFIG. 22 herein.

In FIG. 37, an alternate example media pack 610 from U.S. Ser. No.62/077,749 is depicted, in which a first embossed sheet 611 is securedto a second embossed sheet 612 and then formed into a stacked or coiledmedia pack arrangement, having edge seals generally in accord with FIG.22 herein.

In FIG. 38-40, a third example media arrangement 620 from U.S. Ser. No.62/077,749 is depicted. Edge seals can be conducted in either theupstream end or the downstream end, or in some instances both.Especially when the media is likely to encounter chemical materialduring filtering, it may be desirable to avoid a typical adhesive orsealant.

In FIG. 38, a cross-section is depicted in which the fluted sheet X hasvarious embossments on it for engagement with the facing sheet Y. Againthese can be separate, or sections of the same media sheet.

In FIG. 39, a schematic depiction of such an arrangement between thefluted sheet X and facing sheet Y is also shown.

In FIG. 40, a still further variation of such a principle is shownbetween a fluted sheet X and a facing sheet Y. These are meant to helpunderstand how a wide variety of approaches are possible.

In FIG. 41-43, still another possible variation in fluted sheet X andfacing sheet Y is shown.

In FIGS. 41-43, an example media arrangement 640 is depicted, in which afluted sheet 642 is secured to a facing sheet 643. The facing sheet 643may be a flat sheet. The media arrangement 6401 can then be stacked orcoiled into a media pack, with seals along opposite edges of the typepreviously described for FIG. 22 herein. In the embodiment shown, theflutes 644 of fluted sheet 642 have an undulating ridgeline including aseries of peaks 645 and saddles 646. The peaks 645 of adjacent flutes644 can be either aligned as shown in FIGS. 42 and 43 or offset. Furtherthe peak height and/or density can increase, decrease, or remainconstant along the length of the flutes 644. The ratio of the peak fluteheight to saddle flute height can vary from about 1.5, typically from1.1 to about 1.

It is noted that there is no specific requirement that the same media beused for the fluted sheet section and the facing sheet section. Adifferent media can be desirable in each, to obtain different effects.For example, one may be a cellulose media, while the other is a mediacontaining some non-cellulose fiber. They may be provided with differentporosity or different structural characteristics, to achieve desiredresults.

A variety of materials can be used. For example, the fluted sheetsection or the facing sheet section can include a cellulose material,synthetic material, or a mixture thereof. In some embodiments, one ofthe fluted sheet section and the facing sheet section includes acellulose material and the other of the fluted sheet section and facingsheet section includes a synthetic material.

Synthetic material(s) can include polymeric fibers, such as polyolefin,polyamide, polyester, polyvinyl chloride, polyvinyl alcohol (of variousdegrees of hydrolysis), and polyvinyl acetate fibers. Suitable syntheticfibers include, for example, polyethylene terephthalate, polyethylene,polypropylene, nylon, and rayon fibers. Other suitable synthetic fibersinclude those made from thermoplastic polymers, cellulosic and otherfibers coated with thermoplastic polymers, and multi-component fibers inwhich at least one of the components includes a thermoplastic polymer.Single and multi-component fibers can be manufactured from polyester,polyethylene, polypropylene, and other conventional thermoplasticfibrous materials.

The examples of FIGS. 36-43, are meant to indicate generally that avariety alternate media packs can be used in accord with the principlesherein. Attention is also directed to U.S. Ser. No. 62/077,749incorporated herein by reference, with respect to the general principlesof construction and application of some alternates media types.

E. Additional Media Pack Arrangements Including Pleated Media withFlutes; FIGS. 44-46

Additional examples of alternative types of media arrangements or packsthat involve filtration media having flutes extending between oppositeends or flow faces in a straight through flow configuration are depictedin FIGS. 44-46. The flutes can be considered inlet flutes when they arearranged to receive dirty air via an inlet flow face, and they can beconsidered outlet flutes when they are arranged to permit filtered airto flow out via an outlet flow face.

The filtration media 6502 depicted in FIGS. 44-45B, which is analogousto ones depicted in U.S. Pat. Nos. 8,479,924 and 9,919,256 assigned toMann+Hummel GmbH, is illustrated in an arrangement that shows how thefiltration media 6502 can be formed into a media pack arrangement 6504.

The media pack arrangement 6504 can be considered as having relativelylong or deep pleats from an inlet flow face 6506 to an outlet flow face6508, and can also have varying pleat depths as illustrated. As thedepth of pleats of a media pack increases, there is a tendency of thefiltration media to collapse on each other thereby causing masking.Masking is undesirable because masked filtration media tends to nolonger be available for filtration thereby decreasing dust holdingcapacity and flow through the media pack, and also potentiallyincreasing pressure drop across the media pack. In order to reducemasking and to help the filtration media retain its shape, supportstructures are known to be applied to pleated media. In FIGS. 45A and45B, support sections or spacers 6510 are provided. It should beappreciated that FIGS. 45A and 45B are illustrated in a foldedconfiguration 6512 having pleat folds 6514, but are expanded orseparated to show how the filtration media 6502 and the support sectionsor spacers 6510 can be arranged.

As illustrated in FIGS. 45A-45B, the filtration media 6502 extendsbetween a first side 6516 and a second side 6518. Although only onesupport section 6510 is shown on each pleat face 6520, it should beappreciated that multiple support sections 6510 can be arranged alongeach pleat face 6520 so that when the filtration media 6502 is arrangedinto a media pack as illustrated in FIG. 44 as media pack 604, thevolume between each of the support sections 6510 can be consideredflutes extending between the inlet flow face 6506 and the outlet flowface 6508. The support sections 6510 can be arranged on each flow face6520 so that opposite support sections 6510 contact or engage each otherto help maintain the media pack shape while also limiting the amount offiltration media that would be contacted by the support sections 6510,as illustrated in FIG. 45A. Furthermore, by providing that the supportsections 6510 have adhesive properties, the support sections 6510 can beprovided so that opposing support sections 6510 can adhere to each otherwhen the filtration media 6502 is arranged into the media pack 6504.

The support sections 6510 can be arranged in a tapered configurationwhere support sections 6510 have a cross section at an interior fold6522 and wherein the cross section increases toward an exterior fold6524. In this context, the phrase “interior fold” refers to the side ofthe media that forms an acute angle, and the phrase “exterior fold”refers to the side of the media that forms an obtuse angle when themedia is arranged into a media pack. Furthermore, the reference tochanging the cross section of the support sections 6510 can refer to oneor both of the height that the support section extends away from themedia to which it is adhered and also to the width along the media towhich it is adhered to in a direction toward or away from other supportsections across adjacent flutes. Changing the shape of the supportsections 6510 can help maintain the shape of the media pack and theresulting flutes, and can help reduce the amount of media that wouldotherwise be contacted by the support sections 6510 if they were notarranged in a tapered configuration. In addition, the support sections6510 can be arranged in a non-tapered configuration. As illustrated inFIG. 45B, the support sections 6510 can be provided so that they extendover the exterior folds 6524 although it is not necessary for thesupport sections 6510 to extend over the exterior folds. In addition, itis not necessary for the support sections 6510 to extend into theinterior folds 6522, although, if desired, the support sections 6510 canbe provided so that they extend into the interior folds 6522.

The support sections 6510 can be applied to the filtration media 6502 asadhesive extruded onto the filtration media 6502 where the adhesiveforms the support sections 6510. Before the adhesive has a chance tofully cure, the filtration media 6502 can be folded into the media packarrangement 6504, which may or may not have varying pleat depths. Byforming the media pack arrangement 6504 before the adhesive has fullycured, the opposing support sections 6510 can become bonded or adheredto each other thereby forming flutes extending between the inlet flowface 6506 and the outlet flow face 6508.

It should be appreciated that the filtration media 6502 can be providedwith deformation, such as corrugations, extending across the media. Thedirection of deformation, such as corrugation, can be parallel orperpendicular to the pleat fold direction.

The filtration media 6602 depicted in FIG. 46 is analogous to filtrationmedia depicted in US 2018/02007566 assigned to Champion Laboratories,Inc., as another example of a media pack arrangement 6604 having inletand outlet flutes in a straight through flow arrangement.

The filtration media pack arrangement 6604 can be formed by folding thefiltration media 6602 to form an inlet flow face 6606 and an outlet flowface 6608. The pleat tips 6610 form the inlet flow face 6606, and thepleat tips 6612 form the outlet flow face 6608. Adhesive beads 6616 and6618, which may be continuous or discontinuous, extend along thefiltration media 6602 in multiple lines across the filtration media 6602from a media first side 6620 to a media second side 6622. The adhesivebeads 6616 and 6618 along the media first side 6620 and along the mediasecond side 6620 can be thickened, if desired, and can be arranged toprovide an edge seal along the media first side 6620 and the mediasecond side 6622. By providing that the adhesive beads 6616 and 6618adhere to each other as the filtration media 6602 is folded, inletflutes 6630 and outlet flutes 6632 can be formed in the straight throughmedia pack arrangement 6604.

A similar type of filtration media pack arrangement is commerciallyavailable under the name Enduracube from Baldwin Filters, Inc. Thefiltration media pack available under the name Enduracube from BaldwinFilters, Inc. is arranged in a pleated configuration forming inletflutes and outlet flutes extending between an inlet flow face and anoutlet flow face.

F. Still Further Media Types

Many of the techniques characterized herein will preferably be appliedwhen the media is oriented for filtering between opposite flow ends ofthe cartridge is media having flutes or pleat tips that extend in adirection between those opposite ends. However, alternatives arepossible. The techniques characterized herein with respect to sealarrangement definition can be applied in filter cartridges that haveopposite flow ends, with media positioned to filter fluid flow betweenthose ends, even when the media does not include flutes or pleat tipsextending in a direction between those ends. The media, for example, canbe depth media, can be pleated in an alternate direction, or it can be anon-pleated material.

It is indeed the case, however, that the techniques characterized hereinare particularly advantageous for use with cartridges that arerelatively deep in extension between flow ends, usually at least 100 mm,typically at least 150 mm, often at least 200 mm, sometimes at least 250mm, and in some instances 300 mm or more, and are configured for largeloading volume during use. These types of systems will typically be onesin which the media is configured with pleat tips or flutes extending ina direction between opposite flow ends.

It is also noted that while the techniques described herein weretypically developed for advantageous application and arrangementsinvolving media packs with straight through flow configurations, thetechniques can be applied to advantage in other systems. For example,the techniques can be applied when the cartridge comprises mediasurrounding a central interior, in which the cartridge has an open end.Such arrangements can involve “forward flow” in which air to be filteredenters the central open interior by passage through the media, and theexits through the open end; or, with reverse flow in which air to befiltered enters the open end and then turns and passes through themedia. A variety of such arrangements are possible, including pleatedmedia and alternate types of media. Configurations usable would includecylindrical and conical, among others.

III. Additional Arrangements; FIGS. 47-53

FIG. 48 is a perspective view of a filter arrangement 1020, constructedin accordance with principles of this disclosure. In general, the filterarrangement 1020 includes a first open end cap 1022, an opposite secondend cap 1024, a tubular section of filter media 1026 extending betweenthe end caps 1022, 1024, and a filter cartridge 1160 mounted within anopening in the second end cap 1024.

The filter media 1026 can be many different types, depending on theapplication. In many useful embodiments, the filter media 1026 ispleated. In many useful embodiments, the filter media 1026 is pleatedcellulose. The filter media 1026 is tubular and surrounds an openinterior volume 1028. The tubular shape can have a round cross-section,or it can have other shapes such as oval.

The first end cap 1022 has an opening 1030 in communication with theinterior volume 1028. The second end cap 1024 has an opening 1032 thataccommodates the filter cartridge 1160.

The end caps 1022, 1024 are secured to the ends of the filter media1026. This can be done by molding the end caps 1022, 1024 directly ontothe media 1026, but many alternatives are possible.

In FIG. 48, the first end cap 1022 includes a seal member 1040 to form areleasable seal with a mating part, such as an outlet tube. The sealmember 1040 can be an inwardly directed radial seal member 1042. Theseal member 1040 can be molded as part of the first end cap 22, with asoft polyurethane foam. Alternative seal arrangements are possible,including pinch seals or axial seals.

The filter cartridge 116 includes a media pack 1206. The media pack 1206can include many different types of media including membrane, depthmedia, foam media, pleated, straight-through flow media, z-media, flutedmedia, and any of the various types described in Section II of thisdisclosure, above.

In the example shown in the FIGS., the media pack 1206 includes a firstflow face 1208 and an opposite second flow face 1210 for straightthrough flow.

Flutes 411, 415 (FIG. 22) extend in a direction between the oppositefirst and second flow faces 1208, 1210. A side wall 1212 (FIG. 47)extends between the first and second flow faces 1208, 1210. The sidewall 1212 forms an outer periphery of the cartridge 1016 and can includea hard shell, in some embodiments. In other embodiments, the side wall1212 is the outer wall of the media pack 1206 and is free of a shell.

In this embodiment, the first flow face 1208 corresponds to an inletflow face, while the second flow face 1210 corresponds to an outlet flowface.

The filter cartridge 1016 can either be removable and replaceable in theopening 1032 of the second end cap 1024, or it may benon-removably/permanently mounted therein.

In embodiments in which the cartridge 1016 is non-removably mounted, theend cap 1024 and filter cartridge 1016 are molded together in a singlecontinuous end piece 1240, so that they are one unitary filter element.

In embodiments in which the filter cartridge 1016 is removably mountedin the opening 1032 of the second end cap 1024, there can be a sealmember 1050 radially formed between the sidewall 1212 of the media pack1206 and a radial inner portion of the second end cap 1024. While theseal member 1050 shown in the drawings forms an inwardly directed radialseal, many other types of seals can be formed including a pinch seal oran axial seal.

Preferably, to avoid blocking flow through the pleated media 1026 (i.e.,masking), there will be a minimum and/or controlled distance 1245 (FIG.48) between the outer periphery of the cartridge 1116 and inner wall ofthe pleats 1026 along the interior 1028. For example, the distance 1245can be: at least 0.3 cm; no greater 40% of the diameter of the opening1032; typically less than 5 cm; and typically in a range of 0.5-2 cm.

The media pack 1206 is preferably a coiled media pack, but in otherembodiments, the media pack 1206 can be stacked, as described withrespect to FIG. 32 above. In this embodiment, the media pack 1206 has across-sectional shape that matches the cross-sectional shape of theopenings 1126, 1130 of the end caps 1022, 1024. In this example, theshape is round. In other embodiments, the media pack can be other shapesincluding, for example: non-round, obround, oval, racetrack-shaped,kidney-shaped, conical, frusto-conical, trapezoidal, regular orirregular polygon, banana-shaped; a sector of an annulus with roundedends; or a segment of a circle.

The media pack 1206 extends from the second end cap 1024 into theinterior volume 1028 and toward the first end cap 1022 along anextension less than half of a distance between the first 1022 and secondend caps 1024. In some embodiments, it extends less than one-third ofthe distance between the first 1022 and second 1024 end caps.Alternatives are possible including the media pack 1206 extending fromthe second end cap 1024 into the interior volume 1028 and toward thefirst end cap 1022 along an extension greater than 10%, or greater than20%, or greater than 30%, or greater than 40%, or greater than 50% of adistance between the first 1022 and second end caps 1024.

The filter cartridge 1116 allows for flow of unfiltered fluid, such asair, through the first flow face 1208. The media pack 1206 removesparticulate, and filtered fluid the flows through the second flow face1210 to reach the interior volume 1028 of the filter element 1042.Likewise, unfiltered fluid flows through the filter media 1026 and intothe interior volume 1028, joining the filtered fluid that passed throughthe filter cartridge 1116. From there, the filtered fluid flows throughthe aperture 1040.

In general, advantages are achieved with the filter arrangement 1020over the prior art. For example, the filter cartridge 1116 helps to addlife and more media to both the filter arrangement 1020 without creatinga larger footprint. In addition, having two different media types (e.g.,pleated media 1026 and media 1206) leads to advantages including beingable to filter different particle sizes. The two different media typescan be helpful since they will often having different clogging behaviorin high or low humid conditions. For example, in changing humidityperiods, the different media types (e.g., pleated 1026 and media 1206)can show different loading behavior over time, which can lower theoverall pressure drop by providing more media and two options for thefluid (air) to pass.

Example Alternative Second End Cap, FIGS. 49-53

An alternative embodiment for the filter arrangement is shown in FIGS.49-53 at 1020′. The filter arrangement 1020′ can be the same as thefilter arrangement 1020, described above, except that there is analternative embodiment of the second end cap 1020′.

In FIG. 49, the opening 1032′ in the second end cap 1024′ is off-center.The filter cartridge 1116′ is oriented in the opening 1032′, eitherremovably or permanently. A seal member 1050′ is around the periphery ofthe filter cartridge 1116′. The seal member 1050′ can project from aremaining portion of the end cap 1020′, as can be seen in FIG. 50.

The media pack 1206′ can be any of the various types described above insection II of this disclosure. For example, the media pack 1206′ can bestraight-through flow media, such as fluted media, pleated media,Z-media, membrane, depth media, foam media, and any variation asdescribed in Section II. The outer perimeter shape of the filtercartridge 1116′ is non-round. In the example shown in FIGS. 49-51, theshape can include: a sector of an annulus with rounded ends; a segmentof a circle; a kidney; or a banana.

In some implementations, the filter cartridge 1116′ can be operablyinstalled in a filter housing, in which a portion of the housing has anopening that is sized to receive the axially projecting seal member1050′. The seal member 1050′, in the embodiment shown, is an outwardlyextending radial seal to form a seal between the filter cartridge 1116′and the opening 1032′ in the end cap 1024′. The seal member 1050′, sinceit projects axially from the end cap 1024′ is positioned to form aradially seal with a similar shaped opening (e.g., a sector of anannulus with rounded ends; a segment of a circle; a kidney; or a banana)in a portion of a filter housing, such as either the housing body or ahousing cover. Alternative seals are possible including a radiallyinwardly extending radial seal, axial seal, pinch seal, or acombination. The media pack 1206′ operates to filter any fluid flowingthrough the opening in the housing.

In further examples, the filter cartridge 1116′ is non-removably a partof the end cap 1024′. The seal member 1050′ projects axially from theend cap 1024′ and is positioned to form a removable seal with a similarshaped opening (e.g., a sector of an annulus with rounded ends; asegment of a circle; a kidney; or a banana) in a portion of a filterhousing, such as either the housing body or a housing cover. Theremovable seal can be a radial seal (inward or outward directed), axialseal, or pinch seal.

In further examples, the filter cartridge 1116′ is removably insertedinto the end cap 1024′. There can be a first seal member, in the form ofseal member 1050′, between the filter cartridge 1116′ and the end cap1024′, and a second seal member in the form of seal member 1052 (FIG.52) projecting axially from the end cap 1024′, which is positioned toform a removable seal over an opening, which could be many shapes (e.g.,a sector of an annulus with rounded ends; a segment of a circle; akidney; or a banana) in a portion of a filter housing, such as eitherthe housing body or a housing cover. The first seal member 1050′ betweenthe cartridge 1116′ and the end cap 1024′ can be a radial seal, whilethe second seal member 1052 with the housing part can be an axial seal.The second seal member 1052 can have a periphery of many shapes, such asrectangular as shown in FIG. 52. In an alternative, the filter cartridge1116′ may be a non-removable part of the end cap 1024′.

In the example in FIG. 53, the filter cartridge 1060 is round and madefrom straight-through flow media, including any of the types describedin Section II above including fluted media, pleated media, Z-media,membrane, depth media, foam media. The filter cartridge 1060 is eitherremovably or non-removably positioned in the end cap 1024′. Surroundingthe filter cartridge 1060 is a non-permeable closure material 1062, suchas plastic, including a hard molded plastic. The periphery of theclosure material 1062 can have the shape of a sector of an annulus withrounded ends; a segment of a circle; a kidney; or a banana). The sealmember 1052 is shown surrounding the closure material 1062, whichsurrounds the filter cartridge 1060. The seal member 1052 is shown as anaxial seal. In an alternative, instead of seal member 1052, thisembodiment can include seal member 1050′ forming the periphery of theclosure material 1062 and projecting axially from the end cap 1024′ tobe positioned to form a radially seal with a similar shaped opening(e.g., a sector of an annulus with rounded ends; a segment of a circle;a kidney; or a banana) in a portion of a filter housing, such as eitherthe housing body or a housing cover.

Inventive clauses relating to the second alternative end cap of FIGS.49-53 include:

A filter arrangement comprising: first and second opposite end caps; thefirst end cap having an opening; (b) a tubular section of filter mediaextending between the first and second end caps and defining an interiorvolume therewithin; and a filter cartridge mounted within an opening inthe second end cap.

The filter arrangement as above wherein the filter cartridge has a mediapack comprising media for straight-through flow.

The filter arrangement as above, wherein the filter cartridge has amedia pack comprising flutes.

The filter arrangement as above, wherein the filter cartridge has amedia pack comprising pleats.

The filter arrangement as above, wherein the filter cartridge has amedia pack comprising opposite first and second flow faces with flutesextending in a direction therebetween; and a sidewall extending betweenthe first and second flow faces; at least some of the flutes having anupstream portion adjacent the first flow face being open and adownstream portion adjacent the second flow face being closed; and atleast some of the flutes having an upstream portion adjacent the firstflow face being closed and a downstream portion adjacent the second flowface being open.

The filter arrangement as above wherein the tubular section of filtermedia is pleated media.

The filter arrangement as above wherein the first open end cap includesa radially inwardly directed seal member oriented to form a releasableradial seal.

The filter arrangement as above wherein the filter cartridge isremovably mounted in the opening of the second end cap.

The filter arrangement as above wherein the filter cartridge isnon-removably mounted in the opening of the second end cap.

The filter arrangement as above wherein the media pack in the filtercartridge is coiled.

The filter arrangement as above wherein the media pack of the filtercartridge extends from the second end cap into the interior volume andtoward the first end cap along an extension less than half of a distancebetween the first and second end caps.

The filter arrangement as above wherein the media pack of the filtercartridge extends from the second end cap into the interior volume andtoward the first end cap along an extension less than one-third of adistance between the first and second end caps.

The filter arrangement as above wherein the filter cartridge ispositioned within the opening in the second end cap in an off-centeredposition.

The filter arrangement as above wherein the filter cartridge has anouter perimeter shape that is non-round.

The filter arrangement as above, wherein the filter cartridge has anouter perimeter shape including one of: a sector of an annulus withrounded ends; a segment of a circle; a kidney; or a banana.

The filter arrangement as above wherein the filter cartridge includes aseal member that forms a seal between the opening in the second end capand the filter cartridge.

The filter arrangement as above wherein the seal member includes one ofa: an outwardly extending radial seal member; an inwardly extendingradial seal member; a pinch seal member; or an axial seal member.

The above are example principles. Many embodiments can be made usingthese principles.

1. A filter element comprising: (a) a tubular section of filter media;and (b) first and second opposite open end caps secured to the filtermedia; (i) each of the first and second end caps having a sealarrangement along an inner radial surface of each of the end caps; (ii)each of the seal arrangements including a seal member having an inwardlyradially directed seal surface and a thickness that varies along theseal member surface.
 2. The filter element of claim 1 wherein each theseal arrangements has a same shape as the other.
 3. The filter elementof claim 1 wherein the tubular section of media is conical, and the sealarrangements vary in proportion to each other.
 4. The filter element ofclaim 1 further including a seal support; the seal member beingsupported by the seal support; wherein the seal support comprises aninner liner extending between the first and second end caps.
 5. Thefilter element of claim 1 wherein the thickness of the seal membersurface varies in a radial direction along the seal member surface. 6.The filter element of claim 1 wherein a length of the seal membersurface is constant in an axial direction.
 7. The filter element ofclaim 1 wherein the seal member thickness varies by a minimum thicknessand a maximum thickness, wherein the maximum thickness is at least 1.1times the minimum thickness.
 8. The filter element of claim 1 whereinthe radially directed seal surface comprises a plurality of outwardlyprojecting and axially extending portions and a plurality of inwardlyprojecting and axially extending portions.
 9. The filter element ofclaim 8 wherein the plurality of outwardly projecting and axiallyextending portions and the plurality of inwardly projecting and axiallyextending portions comprise curved portions.
 10. The filter element ofclaim 9 wherein the radially directed seal surface comprises at leasttwo of the radially outwardly projecting and axially extending portionsalternating with at least two of the radially inwardly projecting andaxially extending portions per inch extending around a central axis ofthe filter element.
 11. The filter element of claim 8 wherein theradially directed seal surface comprises greater than 20 of the radiallyoutwardly projecting and axially extending portions alternating withgreater than 20 of the radially inwardly projecting and axiallyextending portions.
 12. The filter element of claim 1 wherein the filtermedia is pleated media.
 13. The filter element of claim 1 wherein thetubular section of filter media has a round cross-section.
 14. A filterassembly comprising: (a) a tube sheet having a filtered air aperture;(b) a tube sheet seal member along the aperture; the seal member havinga plurality of alternating outward radial portions and alternatinginward radial portions; and (c) a filter element releasably secured tothe tube sheet; the filter element having: (i) first and second oppositeend caps; (ii) a tubular section of filter media defining an interiorvolume in communication with the filtered air aperture; and (iii) afirst filter element seal member along the first end cap having aplurality of compressible alternating radial projections and alternatingradial recesses; the first filter element seal member forming a sealwith the tube sheet seal member in that: (A) the tube sheet seal memberinward radial portions receive the first filter element seal memberradial projections; and (B) the first filter element seal member radialrecesses receive the tube sheet seal member outward radial portions. 15.The filter assembly of claim 14 wherein the tube sheet seal member ispart of a seal plate having a collar and a neck; the collar beingattachable to the tube sheet, and the neck projecting axially from thecollar; the tube sheet seal member being along the neck.
 16. The filterassembly of claim 14 further comprising a yoke plate secured to the tubesheet; the yoke plate including a fixture holding a rod removablysecuring the filter element to the tube sheet. 17.-24. (canceled)
 25. Afilter cartridge comprising: (a) a media pack comprising opposite firstand second flow faces with flutes extending in a direction therebetween;and a sidewall extending between the first and second flow faces; (i) atleast some of the flutes having an upstream portion adjacent the firstflow face being open and a downstream portion adjacent the second flowface being closed; and at least some of the flutes having an upstreamportion adjacent the first flow face being closed and a downstreamportion adjacent the second flow face being open; and (b) a band aroundthe sidewall; the band including a plurality of alternating outwardradial portions and alternating inward radial portions.
 26. The filtercartridge of claim 25 wherein the band is between the first flow faceand second flow face. 27.-43. (canceled)
 44. A filter elementcomprising: (a) a tubular section of filter media defining an openfilter interior; and (b) a first open end cap and an opposite second endcap secured to the filter media; (i) the second end cap having a center,integrated gasket with a seal member; the seal member having an inwardlyradially directed seal surface and a thickness that varies along theseal member surface.
 45. The filter element of claim 44 wherein thethickness varies in a radial direction along the seal member surface.46.-65. (canceled)